Development of multifunctional polymer composites with high red mud content

Red mud (RM) is one of the large-scale by-products of alumina production, posing significant environmental challenges due to its high alkalinity, toxicity, and substantial accumulation volumes. The object of this study is polymer composite based on styrene-butadiene aqueous dispersion with RM and chamotte (Pa2) as fillers at high concentrations (up to 90 wt. %). The primary problem addressed in this research is finding effective ways to utilize RM as secondary raw material to enhance its recycling efficiency and create multifunctional materials with adjustable properties. The study established that RM has an irregular plate-like structure with a high active surface area, which facilitates the formation of an open porous composite structure, while Pa2 forms a dense matrix due to its aluminosilicate content. Infrared spectral analysis confirmed the presence of functional groups (OH, Si–O, Al–O) that ensure the interaction of fillers with the polymer matrix. Thermogravimetric analysis demonstrated that RM and Pa2 exhibit similar behavior under heating. Mechanical tests revealed that RM-based composites exhibit high plasticity and energy absorption capacity, whereas Pa2-based composites are characterized by greater stiffness and strength (elastic modulus up to 129.8 MPa). The results indicate that the choice of filler type and concentration effectively regulates composite properties. The proposed approach enables the recycling of industrial waste and the development of multifunctional materials suitable for use in construction, protective coatings, and the production of structural elements capable of withstanding significant loads