Recycling and reusing industrial waste and by-products are topics of great importance across all industries, but they hold particular significance in the metal industry. Aluminum, the most widely used non-ferrous metal globally, generates considerable waste during production, including dross, salt slag, spent carbon cathode and bauxite residue. Extensive research has been conducted to recycle and re-extract the remaining aluminum from these wastes. Given their varied environmental impacts, recycling these materials to maximize residue utilization is crucial. The components of dross, salt slag, and bauxite residue include aluminum and various oxides. Through recycling, alumina can be extracted using processes such as pyrometallurgy and hydrometallurgy, which involve leaching, iron oxide separation, and the production of alumina salt. Initially, the paper will provide a brief introduction to the generation of aluminum residues—namely, dross, salt slag, and bauxite residue—including their environmental impacts, followed by an exploration of their potential applications in sectors such as environmental management, energy, and construction materials.

The potential substitution of Portland cement–based concrete with low- and high-calcium fly ash–based geopolymers was investigated. However, predicting the workability and compressive strength of geopolymers with the desired physical and mechanical properties is a complicated process because of the variety of chemical compositions found in aluminosilicate sources. Therefore, machine-learning techniques were used to predict the physical and mechanical properties of the geopolymers and eliminate the usual trial-and-error laboratory procedures. The experimental and predicted results of geopolymer properties using the multilayer perceptron regressor, voting regressor, and XGBoost techniques were compared. The XGBoost model outperformed the other models in terms of accuracy for predicting workability and compressive strength, producing the R² of 0.96 and 0.89, respectively. Sensitivity analysis determined that the percentage of CaO had the largest effect on geopolymer workability of 27.13%. Fly ash content had the largest effect on compressive strength of 34.44%. Our approach offers a straightforward and dependable strategy for designing and optimizing fly ash–based geopolymers.

This study discusses mechanical properties and analysis of composite materials to develop building bricks for structural lightweight concrete replacement applications made from three different waste materials, i.e. sawdust, polyethylene terephthalate (PET) plastic bottle, and used diaper. All waste materials are used to mixture composite, as cement replacement, with a mixture of 0, 5, 10, 15, and 20 percent of the total weight. This study uses a quantitative method with the sample used as cylindrical tube with 20 mm of diameter and 40 mm of height. Tests were carried out in the form of compressive and specific gravity tests to determine the mechanical and physical properties of the composite material. The use of waste materials as mixtures for composite manufacture with a water per cement ratio of 0.4 at the age of 28 days results in the best compressive strength of 20.70 MPa (5 percent of sawdust), 33.04 MPa (5 percent of PET), and 18.05 MPa (5 percent of used diaper). The density value shows that the addition of waste materials tends to decrease the weight of the composite result. Based on these results, it can be concluded that the use of waste composite materials is a potential replacement for lightweight structural concrete as an effort to reduce the cement requirement for building material applications. DOI: 10.17977/um024v7i22022p092

Geopolymer binders are a promising low-carbon substitute for Portland cement, but their behavior in cold climates remains underexplored. This study investigates the influence of sodium nitrite (NaNO₂) on geopolymer properties cured at −10 °C for 28 days. The binders were formulated from bauxite residue, fly ash, and waste glass, and NaNO₂ was added in various dosages as a chemical admixture. The geopolymer was tested for its setting time, compressive strength, and chemical and morphological characterizations. The addition of the 3 wt% NaNO₂ significantly improved the strength retention in the cold environment, with a compressive strength of 40.7 MPa, compared to a geopolymer without an admixture (26.1 MPa). The X-ray diffraction (XRD) analysis confirmed the presence of gismondine, quartz, and FeSiO₃, with NaNO₂ remaining largely unreacted within the matrix. Fourier Transform Infrared Spectroscopy (FTIR) indicated the presence of Si–O–T bonds in the NaNO₂-modified samples, which showed continued geopolymerization at low temperatures. Scanning electron microscopy (SEM) revealed reduced cracking and a denser microstructure with increasing concentrations of NaNO₂. The results indicate that NaNO₂ not only mitigates the adverse effects of subzero curing but also promotes structure development, and hence it is a viable admixture for enhancing the cold weather durability of geopolymer materials.