This study developed a sustainable high-strength coal gangue backfill material for underground mining applications using coal gangue, fly ash, and cement as primary raw materials, with red mud (RM) as an alternative alkali activator. The mechanical properties of the backfill material were systematically optimized by adjusting coal gangue particle size and alkali activator dosage. The optimized formulation (coal gangue/fly ash/cement = 5:4:1, 3–6 mm coal gangue particle size, 5% RM, which named BF-6-5RM) achieved superior compressive strengths of 8.23 MPa (7 days) and 10.5 MPa (28 days), significantly exceeding conventional backfill requirements and outperforming a CaO-activated reference system (coal gangue/fly ash/cement = 5:4:1, 3–6 mm coal gangue particle size, 2% CaO, which named BF-6-2CaO). Microstructural and physicochemical analyses revealed that both formulations produced calcium silicate hydrate gels (C-S-H gels) and ettringite (AFt) as key hydration products, though BF-6-5RM exhibited a denser microstructure with well-developed ettringite networks and no detectable portlandite (CH), explaining its enhanced early-age strength. Environmental assessments confirmed effective heavy metal immobilization via encapsulation, adsorption, precipitation and substitution, except for arsenic (As), which exceeded Class III groundwater thresholds (DZ/T 0290-2015) due to elevated raw material content, displaying “surface wash-off, diffusion and depletion” leaching behavior. The findings confirm that red mud-based alkali activation is a viable technology for underground backfilling, provided it is coupled with arsenic control strategies like chemical stabilization or the selection of low-arsenic raw materials. This approach not only enables the resource utilization of hazardous industrial waste but also facilitates the production of backfill materials that combine both mechanical strength and environmental compatibility, thereby delivering dual economic and ecological benefits for sustainable mining practices.

Coal gasification slag (CGS), a massive industrial solid waste, possesses inherent adsorptive potential that remains underutilized due to pore blockage by amorphous siliceous phases. Conventional modification strategies typically rely on energy-intensive high-temperature processes. Herein, we report a facile, low-temperature alkaline activation approach to transform CGS into a high-efficiency adsorbent (denoted NCGS) for Cd²⁺ removal. Sodium hydroxide (NaOH) solution was employed under mild conditions (90 °C) to selectively etch siliceous species, thereby generating a porous architecture and enriching surface oxygen-containing functionalities. Orthogonal experimental design identified optimal synthesis parameters (1 mol/L NaOH, solid–liquid ratio of 1:30 g/mL, 12 h), yielding NCGS with significantly enhanced textural properties. The adsorption isotherm was well described by the Langmuir model, with a maximum capacity of 87.06 mg/g at pH 6.0, while kinetic studies indicated the adsorption process could be described by pseudo-second-order kinetic model. Comprehensive characterization via SEM-EDS, FTIR, and XPS elucidated a multi-mechanistic adsorption pathway mainly involving ion exchange (Na⁺/Cd²⁺) and coordination complexation. Life cycle assessment analysis revealed that NCGS production generates 11.23 kg CO₂ eq emissions, with transportation accounting for 88%. This study presents an energy-saving and environmentally friendly strategy to unlock the adsorptive potential of CGS, providing a highly promising waste-based adsorption material for the remediation of Cd²⁺-contaminated water.