Field-tested innovation: Sustainable utilization of secondary alumina dross for flash setting admixtures production

Secondary alumina dross (SAD) has emerged as an alternative to bauxite in the production of flash setting admixtures (FSA), a critical admixture in shotcrete. However, the presence of hazardous components has hampered its large-scale adoption. This study conducted field tests at an FSA factory, utilizing SAD as the primary raw material, to evaluate the feasibility and environmental risks. The results confirmed that SAD can effectively replace bauxite in FSA production without compromising quality, as it closely resembled the chemical properties of bauxite. Emissions of fluorides, heavy metals, dioxins in flue gases during production met the relevant Chinese standards. The analysis of hazardous component distribution revealed that more than 50% of volatile components, such as Cl, Cd, Pb, and Zn, were directed into fly ash, exhibiting a significant internal accumulation pattern. In contrast, more than 95% of low-volatility components, including Cu, Cr, Mn, and F, were transferred to the FSA, and the introduction of CaCO₃ was confirmed to effectively immobilize F. Moreover, the leaching risk of heavy metals and fluorides in FSA applications slightly increased but remained minimal and within acceptable limits. This technology provides an environmentally sound solution for the disposal of SAD.