Reaction of bauxite residue with seawater results in neutralization of alkalinity through precipitation of Mg-, Ca-, and Al-hydroxide and carbonate minerals. In batch studies, the initial pH neutralization reaction was rapid (<5 min), with further reaction continuing to reduce pH for several weeks. Reaction with seawater produced a residue pH of 8 to 8.5. Laboratory leaching column studies were undertaken to provide information on seawater neutralization of the coarse-textured fraction of the waste, residue sand (RS), under conditions comparable with those that might be applied in the field. An 0.80-m-deep column of RS was neutralized by the application of the equivalent of 2-m depth of seawater. In addition to lowering the pH and Na content of the residue, seawater neutralization resulted in the addition of substantial amounts of the plant nutrients Ca, Mg, and K to the profile. Similar results were also obtained from a field-scale assessment of neutralization. However, the accumulation of precipitate, consisting of hydrotalcite, aragonite, and pyroaurite, in the drainage system may preclude the use of in situ seawater neutralization as a routine rehabilitation practice. Following seawater neutralization, RS remains too saline to support plant growth and would require fresh water leaching before revegetation.

Alumina extraction from bauxite ore with strong alkali produces waste bauxite refinery residue consisting of residue sand and red mud. The amount and composition of refinery residue depend on the purity of the bauxite ore and extraction conditions, and differs between refineries. The refinery residue is usually stored in engineered disposal areas that eventually have to be revegetated. This is challenging because of the alkaline and sodic nature of the residue. At Alcan Gove's bauxite refinery in Gove, Northern Territory, Australia, research into revegetation of bauxite residue has been conducted since the mid-1970s. In this review, we discuss approaches taken by Alcan Gove to achieve revegetation outcomes (soil capping of refinery residue) on wet-slurry disposal areas. Problems encountered in the past include poor drainage and water logging during the wet season, and salt scalding and capillary rise during the dry season. The amount of available water in the soil capping is the most important determinant of vegetation survival in the seasonally dry climate. Vegetation cover was found to prevent deterioration of the soil cover by minimising capillary rise of alkalinity from the refinery residue. The sodicity and alkalinity of the residue in old impoundments has diminished slightly over the 25 years since it was deposited. However, development of a blocky structure in red mud, presumably due to desiccation, allows root penetration, thereby supplying additional water to salt and alkali-tolerant plant species. This has led to the establishment of an ecosystem that approaches a native woodland.

Survival of vegetation on soil-capped mining wastes is often impaired during dry seasons due to the limited amount of water stored in the shallow soil capping. Growth and survival of Rhodes grass (Chloris gayana) during soil drying on various layered capping sequences constructed of combinations of topsoil, subsoil, seawater-neutralised residue sand and low grade bauxite was determined in a glasshouse. The aim was to describe the survival of Rhodes grass in terms of plant and soil water relationships. The soil water characteristic curve and soil texture analysis was a good predictor of plant survival. The combination of soil with a high water holding capacity and low soil water diffusivity (e.g. subsoil with high clay contents) with soil having a high water holding capacity and high diffusivity (e.g. residue sand) gave best survival during drying down (up to 88 days without water), whereas topsoil and low grade bauxite were unsuitable (plants died within 18-39 days). Clayey soil improved plant survival by triggering a water stress response during peak evaporative water demand once residue sand dried down and its diffusivity fell below a critical range. Thus, for revegetation in seasonally dry climates, soil capping should combine one soil with low diffusivity and one or more soils with high total water holding capacity and high diffusivity.

The solubilities and dissolution rates of 3 gypsum sources [analytical grade reagent (AR), phosphogypsum (PG), mined gypsum (MG)] with 6 MG size fractions (>2.0, 1.0–2.0, 0.5–1.0, 0.25–0.5, 0.125–0.25, <0.125 mm) were investigated in triple-deionised water (TDI) and seawater to examine their suitability for bauxite residue amelioration. Gypsum solubility was greater in seawater (3.8 g/L) than TDI (2.9 g/L) due to the ionic strength effect, with dissolution in both TDI and seawater following first-order kinetics. Dissolution rate constants varied with gypsum source (AR > PG > MG) due to reactivity and surface area differences, with 1 : 20 gypsum : solution suspensions reaching saturation within 15 s (AR) to 30 min (MG >2.0 mm). The ability of bauxite residue to adsorb Ca from solution was also examined. The quantity of the total solution Ca adsorbed was found to be small (5%). These low rates of solution Ca adsorption, combined with the comparatively rapid dissolution rates, preclude the application of gypsum to the residue sand/seawater slurry as a method for residue amelioration. Instead, direct field application to the residue would ensure more efficient gypsum use. In addition, the formation of a sparingly soluble CaCO3 coating around the gypsum particles after mixing in a highly alkaline seawater/supernatant liquor solution greatly reduced the rate of gypsum dissolution.

Processing of bauxite to extract alumina produces a strongly alkaline waste, bauxite refining residue, which is commonly stored in engineered structures. Once full, these waste dumps must be revegetated. In many alumina refineries, the waste is separated into fine-textured red mud and coarse-textured residue sand (RS). The sand component has physical characteristics that make it a suitable plant growth medium, provided the adverse chemical characteristics can be addressed. Neutralization of the highly saline-sodic RS with sea water lowers pH, reduces Na saturation, and adds plant nutrients. However, sea water-neutralized RS remains saline sodic and needs fresh water leaching before use as a plant growth medium. Columns containing sea water-neutralized RS were leached with 30 m depth-equivalent of fresh water to evaluate the effects of rainfall on the RS and its leachate. Entrained cations were rapidly displaced by the fresh water, lowering salinity to non-plant-limiting levels (< or =0.3 dS m(-1)). The percentage of the effective cation exchange capacity (ECEC) saturated by Na decreased from 71 to 62% due to a reduction in soil solution ionic strength (causing a decrease in the ECEC) and the preferential displacement of Na(+) (and K(+)) from the exchange. Fresh water leaching increased pH (leachate pH increased from 8.0 to 10.1). This pH increase is attributed to the slow dissolution of the Na-containing mineral sodalite. Under the current experimental conditions, the application of 30 m depth-equivalent of leaching reduced the total RS sodalite content by <10%.