This paper identifies the spatial extent of bauxite processing residue (red mud)-derived contaminants and modes of transport within the Marcal and Rába river systems after the dike failure at Ajka, western Hungary. The geochemical signature of the red mud is apparent throughout the 3076 km² Marcal system principally with elevated Al, V, As, and Mo. Elevated concentrations of Cr, Ga, and Ni are also observed within 2 km of the source areas in aqueous and particulate phases where hyperalkalinity (pH < 13.1) is apparent. Although the concentrations of some trace elements exceed aquatic life standards in waters (e.g., V, As) and fluvial sediments (As, Cr, Ni, V), the spatial extent of these is limited to the Torna Creek and part of the upper Marcal. Source samples show a bimodal particle size distribution (peaks at 0.7 and 1.3 μm) which lends the material to ready fluvial transport. Where elevated concentrations are found in fluvial sediments, sequential extraction suggests the bulk of the As, Cr, Ni, and V are associated with residual (aqua-regia/HF digest) phases and unlikely to be mobile in the environment. However, at some depositional hotspots, association of As, Cr, and V with weak acid-extractable phases is observed.

In the 5 years since the 2010 Ajka red mud spill (Hungary), there have been 46 scientific studies assessing the key risks and impacts associated with the largest single release of bauxite-processing residue (red mud) to the environment. These studies have provided insight into the main environmental concerns, as well as the effectiveness of remedial efforts that can inform future management of red mud elsewhere. The key immediate risks after the spill were associated with the highly caustic nature of the red mud slurry and fine particle size, which once desiccated, could generate fugitive dust. Studies on affected populations showed no major hazards identified beyond caustic exposure, while red mud dust risks were considered equal to or lesser than those provided by urban dusts of similar particle size distribution. The longer-term environmental risks were related to the saline nature of the spill material (salinization of inundated soils) and the release and the potential cycling of oxyanion-forming metals and metalloids (e.g., Al, As, Cr, Mo, and V) in the soil-water environment. Of these, those that are soluble at high pH, inefficiently removed from solution during dilution and likely to be exchangeable at ambient pH are of chief concern (e.g., Mo and V). Various ecotoxicological studies have identified negative impacts of red mud-amended soils and sediments at high volumes (typically [5 %) on different test organisms, with some evidence of molecularlevel impacts at high dose (e.g., genotoxic effects on plants and mice). These data provide a valuable database to inform future toxicological studies for red mud. However, extensive management efforts in the aftermath of the spill greatly limited these exposure risks through leachate neutralization and red mud recovery from the affected land. Monitoring of affected soils, stream sediments, waters and aquatic biota (fungi, invertebrates and fish) have all shown a very rapid recovery toward prespill conditions. The accident also prompted research that has also highlighted potential benefits of red mud use for critical raw material recovery (e.g., Ga, Co, V, rare earths, inform), carbon sequestration, biofuel crop production, and use as a soil ameliorant.

Red mud can be applied as soil ameliorant to acidic, sandy and micronutrient deficient soils. There are still knowledge gaps regarding the effects of red mud on the soil microbial community. The Biolog EcoPlate technique is a promising tool for community level physiological profiling. This study presents a detailed evaluation of Biolog EcoPlate data from two case studies. In experiment "A" red mud from Ajka (Hungary) was mixed into acidic sandy soil in soil microcosms at 5-50 w/w%. In experiement "B" red mud soil mixture was mixed into low quality subsoil in a field experiment at 5-50 w/w%. According to average well color development, substrate average well color development and substrate richness 5-20% red mud increased the microbial activity of the acidic sandy soil over the short term, but the effect did not last for 10 months. Shannon diversity index showed that red mud at up to 20% did not change microbial diversity over the short term, but the diversity decreased by the 10 th month. 30-50% red mud had deteriorating effect on the soil microflora. 5-20% red mud soil mixture in the low quality subsoil had a long lasting enhancing effect on the microbial community based on all Biolog EcoPlate parameters. However, 50% red mud soil mixture caused a decrease in diversity and substrate richness. With the Biolog EcoPlate we were able to monitor the changes of the microbial community in red mud affected soils and to assess the amount of red mud and red mud soil mixture applicable for soil treatment in these cases.

Since the world economy has been confronted with an increasing risk of supply shortages of critical raw materials (CRMs), there has been a major interest in identifying alternative secondary sources of CRMs. Bauxite residues from alumina production are available at a multi‐million tonnes scale worldwide. So far, attempts have been made to find alternative re‐use applications for bauxite residues, for instance in cement / pig iron production. However, bauxite residues also constitute an untapped secondary source of CRMs. Depending on their geological origin and processing protocol, bauxite residues can contain considerable amounts of valuable elements. The obvious primary consideration for CRM recovery from such residues is the economic value of the materials contained. However, there are further benefits from re‐use of bauxite residues in general, and from CRM recovery in particular. These go beyond monetary values (e.g. reduced investment / operational costs resulting from savings in disposal). For instance, benefits for the environment and health can be achieved by abatement of tailing storage as well as by reduction of emissions from conventional primary mining. Whereas certain tools (e.g. life‐cycle analysis) can be used to quantify the latter, other benefits (in particular sustained social and technological development) are harder to quantify. This review evaluates strategies of bauxite residue re‐use / recycling and identifies associated benefits beyond elemental recovery. Furthermore, methodologies to translate risks and benefits into quantifiable data are discussed. Ultimately, such quantitative data are a prerequisite for facilitating decision‐making regarding bauxite residue re‐use / recycling and a stepping stone towards developing a zero‐waste alumina production process. © 2018 The Authors. Journal of Chemical Technology & Biotechnology published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry.

BACKGROUND Red mud is a by‐product of alumina extraction from bauxite by the Bayer process produced in the billion tons scale worldwide. Red muds, or more generally bauxite residues, are regarded as waste, but may potentially be valuable sources of critical raw materials (CRM). In the present study both conventional extracting agents (mineral acids) and small molecular weight complexing agents (organic acids) were evaluated regarding their efficiency to extract CRM such as rare earth elements (REEs) from red mud. On a molar base, highest extraction efficiencies for REEs were achieved using HCl compared with the other acids investigated. Consequently, an experimental design approach was used to determine optimal conditions for CRM extraction using HCl. Instead of maximizing the extraction of a number of selected metals, the maximum economic potential as the sum of all metals (total metal extracted × economic value of the respective metal) was chosen as the application relevant response variable. Four explanatory variables (i.e. HCl concentration, contact time, temperature and slurry concentration) were used. RESULTS Optimal conditions maximizing the economic potential were predicted for 5.98 mol L−1 HCl, 21 h contact time, 50°C, and 56.7 g L−1 slurry concentration. Indeed, experimentally determined economic potential corresponded well (71% of predicted) with the predictions, allowing a maximum recovery of 297.6 US $ t−1. CONCLUSION Though the studied red muds were relatively low in CRM concentrations, the systematic approach developed here allows straightforward transfer to other red muds, harnessing the potential of the latter as important secondary source for CRM. © 2017 Society of Chemical Industry