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.

This paper presents a numerical investigation regarding the possibility of using electrically conductive concrete (ECON) combined with concrete-encased electrode (CEE) technology to develop new substation grounding systems (SGSs) called ECON-EE as a replacement for conventional copper or galvanized steel grounding grids. In the first step, the validation of the commercial FEM software used to perform grounding system analysis was performed in terms of the grid resistance (R_G), ground potential rise (GPR), and step and touch voltages, using a symmetrical 70 m × 70 m conventional copper SGS. Next, several numerical simulations of an ECON-EE grounding system with the same dimensions as the conventional copper grid used for FEM software validation were performed. Thus, several parameters of the ECON-EE grounding system were studied, such as the geometry, dimensions, and resistivity of ECON and the diameter of the rebar. The numerical results obtained permit us to demonstrate that ECON-EE grounding systems can perform better than conventional SGSs equipped with vertical rods, particularly in the case of high ground resistivity. Moreover, it was demonstrated that the two main ECON-EE parameters affecting the grounding resistance and the touch and step voltages are the section area and the resistivity of the ECON. As discussed in detail in this paper, the proposed ECON-EE grounding system can offer several advantages compared to conventional SGSs in terms of efficiency and durability, as well as in terms of simplicity of conception and implementation.

The growing demand for sustainable and multifunctional construction materials, particularly those capable of addressing durability and energy challenges, has motivated the development of conductive and photothermally active geopolymers. This study investigated the use of an Fe-rich spinel aggregate (FSA) as a high-density filler in geopolymers composed of ground granulated blast furnace slag and bauxite residue, with a fixed addition of 1 wt% graphite (binder-based) to enhance electrical conductivity. The effects of different FSA replacement percentages (0–100%) on compressive strength, electrical conductivity, photothermal efficiency, and chemical resistance were evaluated. An increase in the FSA content translated to an increase in the final compressive strength, with 100% FSA replacement achieving the highest value of 45.5 ± 2.5 MPa at 28 days. As the FSA content increased, the electrical resistivity decreased to as low as 42 Ω·m at 100% replacement. Under simulated solar flux conditions (1 kW/m²), photothermal analysis revealed that the 100% FSA mixtures exhibited the highest surface temperature increase of 9.8 °C after 300 s, indicating their superior thermal responsiveness. Furthermore, acid immersion in 10% HCl for 28 days showed mass gain in all geopolymers, with the highest gain observed at 50% FSA (+11.51%). Similarly, the strength increased after acid exposure up to a 75% FSA content. These findings highlight the multifunctional potential of FSA-enhanced geopolymers for high-mechanical-performance, electrically conductive, photothermally active, and chemically durable materials as multifunctional construction materials.

This paper presents a numerical investigation studying the response of a new grounding system when submitted to different lightning current waveforms. This grounding system features an electrically conductive concrete (ECON) or geopolymer (ECG) square section with a standard steel rebar as an encased electrode (EE) at the center to potentially replace conventional copper or galvanized steel grounding grids in HV substations. Due to the specificity of this new grounding system called ECON/ECG-EE, we decided to perform different transient simulations using the RF module of the general FEM software Comsol Multiphysics 6.2 version. In the first step, both frequency (FD) and temporal domain (TD) analyses were validated using three grounding systems extracted from the literature. Next, several numerical new grounding system simulations were performed and compared with a conventional HV substation copper grid of the same dimensions equipped with vertical rods. We investigated the influence of several parameters, such as ECON/ECG and soil electrical conductivity, the rise-time in current lightning waveform and the frequency dependency of soil parameters. The numerical results obtained demonstrate that ECON/ECG-EE grounding systems submitted to lightning current pulse present a smaller peak impedance than conventional SGSs equipped with vertical rods, particularly in cases with high soil resistivity. Moreover, it was also demonstrated that with faster lightning current pulse, the ECON/ECG system’s peak impedance becomes significantly lower than those obtained for a copper grid with vertical rods.