As one of the main industrial solid wastes, there are a large number of free alkaloids, chemically bound alkaloids, fluoride, and heavy metal ions in Bayer process red mud (BRM), which are difficult to remove and easily pollute groundwater as a result of open storage. In order to realize the large-scale industrial application of BRM as a backfilling aggregate for underground mining and simultaneously avoid polluting groundwater, the material characteristics of BRM were analyzed through physical, mechanical, and chemical composition tests. The optimum cement–sand ratio and solid mass concentration of the backfilling were obtained based on several mixture proportion tests. According to the results of bleeding, soaking, and toxic leaching experiments, the fuzzy comprehensive evaluation method was used to evaluate the environmental impact of BRM on groundwater. The results show that chemically bound alkaloids that remained in BRM reacted with Ca²⁺ in PO 42.5 cement, slowed down the solidification speed, and reduced the early strength of red mud-based cemented backfill (RMCB). The hydration products in RMCB, such as AFT and C-S-H gel, had significant encapsulation, solidification, and precipitation inhibition effects on contaminants, which could reduce the contents of inorganic contaminants in soaking water by 26.8% to 93.8% and the leaching of toxic heavy metal ions by 57.1% to 73.3%. As shown by the results of the fuzzy comprehensive evaluation, the degree of pollution of the RMCB in bleeding water belonged to a medium grade Ⅲ, while that in the soaking water belonged to a low grade II. The bleeding water was diluted by 50–100 times to reach grade I after flowing into the water sump and could be totally recycled for drilling and backfilling, thus causing negligible effects on the groundwater environment.

Red mud is a by-product of alumina production, and its disposal can have severe environmental consequences. This study experimentally investigates the feasibility of using red mud from the Bayer process for cemented paste backfill (CPB). Different binders and activators were used to improve the mechanical properties, water resistance, and environmental behaviors of red mud-based CPB. In addition, water immersion tests were introduced, for the first time, to evaluate the water resistance of CPB. Furthermore, the environmental behaviors of red mud-based CPB were investigated by conducting leaching experiments. The results showed that the red-mud specimens had an unconfined compressive strength (UCS) of less than 0.2 MPa and disintegrated after being immersed in water. Different binders significantly improved the mechanical properties of red mud-based CPB. In addition, the specimens with different binders showed excellent water resistance, and the softening coefficient of CPB with different binders could exceed 0.7 after being cured for 28 days. The binders exhibited a substantial inhibitory effect on the leaching of hazardous substances in red mud under the solidification and stabilization effects. The leaching concentration of hexavalent chromium, selenium, fluoride, arsenic, lead, and vanadium was reduced by more than 70%. Therefore, this study provides an effective method for the environmental-friendly and large-scale utilization of red mud from the Bayer process.