High-temperature structural drivers immobilizing alkaline substances in red mud-derived mineral wool

Smelting and fiberization of red mud (RM) is an attractive approach for rapid recovery of metal resources, production of mineral wool, and immobilization of hazardous alkalis. However, an enormous challenge remains in understanding alkali immobilization behavior in mineral wool over a broad A/S (Al₂O₃ to SiO₂ mass ratio) range. Here we addressed the challenge through molecular dynamics, thermodynamic and experimental analyses. Increasing A/S ratio caused an increasing degree of structural order and the remarkable micro-phase separation occurred at A/S > 0.9. The role of Na⁺ and Ca²⁺ changed from the network-modifying cations to the charge-compensating cations. Melt viscosity decreased and then increased significantly with an intensified temperature sensitivity, identified by the increasing viscous flow activation energy from 211.5 to 377.03 kJ/mol in the temperature region from 1500 to 1570 °C. The transformation of thermodynamic properties (real mixed/excess molar Gibbs free energies, and entropy increment) corresponded to the structural changes. Thermal, mechanical and leaching tests confirmed the negative effect of this structural transformation on alkali immobilization. The A/S ratios controlled below 0.9 were proposed for environmental benefits and product stability. The investigation of immobilization mechanism provides valuable information for tuning the vitrification chemistry and developing safe and green mineral wool from RM.