Spatiotemporal Evolution of Red Mud Flocculated Structure During Self-Weighted Siltation and Macro–Micro Correlation Modeling

In high-concentration tailings backfilling, the stability of the backfill largely depends on the slurry’s self-weighted siltation behavior. Red mud—the strongly alkaline by-product of the Bayer process and a mixture of coarse and fine particles—requires a clear understanding of its self-weight settling–consolidation mechanisms to ensure safe and efficient backfilling. In this study, red mud slurry was selected as the research object, and a multi-scale approach combining sedimentation column tests and microstructural image analysis was employed to reveal the intrinsic relationships among the sediment layer height, sedimentation rate, and pore structure changes during self-weighted siltation. The results show that the flocculated structure of red mud slurry exhibits distinct stratification during self-weighted siltation, including a clarified layer, a structural transition layer, and a dense sediment layer. During the siltation process, the sediment layer height, sedimentation rate, and floc structure of red mud evolve nonlinearly. The addition of flocculants significantly enhances the formation rate of flocculated structures but increases the porosity of the sediment body. At the macroscopic level, this results in a shortened self-weighted siltation time and increased final sediment layer height. To describe the regulatory effect of flocculants on red mud floc structure, a macro–micro predictive model for the sediment layer height was established by introducing a structural enhancement coefficient, considering the effect of flocculants. The model achieved a prediction error within 16%. These findings provide theoretical support for structural control technologies and process optimization of high-concentration fine tailings backfilling, thereby contributing to the sustainable utilization of red mud and the development of environmentally responsible backfilling practices.