Red mud, a waste byproduct of aluminum production, is accumulating rapidly, with an estimated annual production of up to 175 million tonnes in 2022. The potential valorization of rare earth elements contained in red mud is significant, valued at approximately 4.3 trillion USD$. This makes red mud a highly underutilized resource for metal recovery. Additionally, traditional storage methods such as dry and wet stacking pose substantial environmental risks due to the fine particle size and high alkalinity of red mud, which could lead to severe environmental degradation and social ramifications in the event of storage failure.
In this study, charcoal was produced from the abundant and cost-effective biomaterial, Luffa cylindrica, using slow pyrolysis in a fixed bed reactor. A Central Composite Design (CCD) was employed to create an experimental set up to investigate the response of biochar yield and Iodine Number as a function of the operating parameters, pyrolysis temperature and time, in an interval of 400-600 °C and 60-90 minutes, respectively. The CCD results indicated a significant dependence on temperature for both yield and iodine number, with a confidence level of 0.9. The relative variance in charcoal yield with respect to pyrolysis time and temperature was much lower than that of the iodine number, at 21% versus 110%, respectively. The CCD model was subsequently optimized to maximize the iodine number, yielding an optimal response at 450 °C and 75 minutes.
The charcoal produced under optimal conditions underwent characterization using Scanning Electron Microscopy (SEM), Brunauer-Emmett-Teller (BET) and Raman spectroscopy. The analysis revealed that the charcoal exhibited modest porosity and structural disorder, with an intensity ratio (ID/IG) of 0.85.
Adsorption experiments were performed at a contact time of 24 h, under a constant stirring rate of 200 rpm, using both Luffa cylindrica derived charcoal and commercial activated carbon, which has a much higher surface area. The results elucidated that surface area was not the limiting factor in the adsorption experiment, as neither type of charcoal demonstrated significant adsorption of the investigated metals. Fourier Transform Infrared (FTIR) analysis indicated structural modifications and oxidation of the charcoal, suggesting that the investigated pH range could inhibit adsorption. The only species detected from adsorption were low amounts of chloride ions, indicating that limited affinity and charcoal deterioration were the primary limiting factors in the adsorption experiment. For future research, it is recommended to conduct charcoal adsorption experiments at higher pH levels and to explore methods to enhance the affinity between the charcoal adsorbent and metal species. One promising approach is to increase the surface-active groups (SOCs) on the charcoal, which have a high affinity for metal ions in aqueous solutions, using oxidizing media such as ozone or nitric acid.