Clean Technologies

Access to safe drinking water remains a global challenge, particularly in decentralized and low-resource settings where conventional treatment technologies may be economically or operationally impractical. Combining low-energy hydraulic flocculation systems with biodegradable natural coagulants represents a promising strategy for sustainable water treatment. This study investigated the influence of hydraulic retention time (HRT) on the clarification performance of aluminum sulfate, Moringa oleifera, and Aloe vera in continuous-flow helically coiled tube flocculators (HCTFs). Four HRTs (1.71–6.84 min) were obtained by varying reactor length while maintaining a constant flow rate of 0.5 L/min. Synthetic water with an initial turbidity of approximately 100 NTU was treated, and clarification performance was evaluated by residual turbidity and turbidity removal efficiency. Two-way ANOVA revealed significant effects of HRT and coagulant type, as well as a significant interaction between these factors (p < 0.001), indicating that the influence of HRT depended on the dominant coagulation mechanism. Aluminum sulfate maintained consistently high turbidity removal efficiencies (96.3–98.1%) regardless of HRT. In contrast, Moringa oleifera achieved the highest clarification efficiency (99.5%) and a final turbidity of 0.49 NTU at the longest HRT, whereas Aloe vera exhibited the greatest hydraulic sensitivity, with turbidity removal increasing from 78.9% to 96.1% as HRT increased. The results demonstrate that HRT should be selected according to the dominant coagulation mechanism of the coagulant rather than adopted as a fixed design parameter. This mechanism-based approach provides a rational basis for designing and optimizing continuous-flow flocculators and supports the development of compact, efficient, and sustainable decentralized water treatment systems. Full article

Poly(lactic acid) (PLA) is a renewable and biodegradable polymer that has attracted considerable attention for sustainable packaging applications. However, its inherent brittleness limits its use in flexible films. In this study, PLA/poly(vinyl alcohol) (PVA) blend films were prepared by a single-solvent-casting rout at PLA/PVA weight ratios of 80/20, 70/30, 60/40, and 50/50 to investigate the influence of composition on their thermal, chemical, morphological, mechanical, optical, and water vapor barrier properties. Increasing the PVA content progressively modified the molecular organization of the system, the crystallization ability of the PLA phase and promoting a more homogeneous phase distribution. These structural changes resulted in a transition from a brittle behavior to increasingly ductile films, with the PLA/PVA 50/50 composition exhibiting the most favorable combination of tensile toughness, transparency, and morphological homogeneity, reaching an elongation at break of approximately 60%. In contrast, the increase in the hydrophilic phase led to higher water vapor permeability, highlighting the trade-off between mechanical performance and moisture barrier properties. Overall, the results demonstrate that controlling the PLA/PVA ratio provides an effective strategy for tailoring the morphology and functional properties of solvent-cast PLA/PVA films, contributing to a better understanding of the composition–structure–property relationships in biopolymer blends. Full article

The growing volume of crustacean shell waste generated during seafood processing poses a serious environmental problem. However, this type of biowaste remains underutilized, despite being a promising renewable raw material for the production of functional carbon materials. This study aims to investigate how synthesis parameters influence the formation of a hierarchical porous structure in shrimp shell-based carbon materials and to optimize these parameters to improve CO₂ adsorption efficiency. Under optimal carbonization conditions (holding time: 2 h; temperature: 650 °C) and activation conditions (holding time: 2 h; temperature: 750 °C) with activator-to-carbon weight ratios (A/C) of 1/1, 2/1 and 4/1, the resulting porous carbon samples exhibited relatively high S_BET values (1175, 2708 and 3052 m²/g, respectively) and V_T (0.70, 1.55 and 2.60 cm³/g, respectively), as well as different pore size distributions. Notably, the resulting carbon materials demonstrated exceptional CO₂ adsorption performance at 298 K, reaching a maximum adsorption capacity of 40.03 mmol/g at 40 bar for sample SS_652_41752, 15.12 mmol/g at 15 bar for SS_652_21752, and 3.41 mmol/g at 1 bar for SS_652_11752. These values rank among the highest ever reported for biomass-derived porous carbon materials. The adsorption behavior of the most efficient sorbent, SS_652_41752, was further analyzed using Langmuir and Freundlich isotherm models over the temperature range of 298–318 K and at pressures up to 40 bar, and the isosteric heats of adsorption were calculated to elucidate adsorbent–adsorbate interactions. It was found that the differential molar isosteric heat of CO₂ adsorption decreased from approximately 20 to approximately 17 kJ/mol with increasing adsorption uptake, confirming the physisorption nature of the process. These results demonstrate that crustacean shell waste is a promising feedstock for producing carbon materials with tailored properties and significant potential for CO₂ adsorption applications. Full article

The fastest growing waste stream worldwide is represented by Waste from Electrical and Electronic Equipment (WEEE). One of the main critical issues related to the recovery of such waste is the mixed plastic fraction, which is difficult to sort and can contain flame retardants and additives that pose a risk to human health and the environment. This study aims to validate the possibility of using tribo-electrostatic separator technologies to sort plastic polymers (e.g., PP, PA6, PS and PVC) obtained after a size-reduction operation of WEEE. The experimental study was conducted on a 10 kg/h laboratory-scale pilot plant. Several parameters were analysed during the tribo-charging and electrostatic separation processes, including the rotation speed and residence time of the particles in the tribo-charging device as well as electrode voltage, and the distance between the deflectors and the electrodes in the electrostatic separator. The results show that the tribo-electrostatic separation technologies are promising and efficient for plastic waste recycling. In fact, under specific conditions, it is possible to achieve high recovery rates (>70%) and purity levels (>76%) that allow the reintegration of plastic polymers into the economic cycle as a secondary raw material. Full article

This work presents a techno-economic assessment of hydrogen production via sorption-enhanced gasification (SEG) of hazelnut shells across three plant scales (100 kWth, 1 MWth, and 10 MWth). The overall model is developed through the integration of Aspen Plus^® process simulation, coupled with MATLAB^®-based kinetic reactor modelling, enabling the assessment of the entire process chain. The kinetic SEG model, validated against experimental literature data, was implemented to describe the fluidized bed gasifier behaviour at the three scales. The resulting process streams were subsequently integrated into Aspen Plus^® for downstream upgrading and overall system analysis. The simulations show that the SEG process produces a hydrogen-rich syngas with H₂ contents around 80 vol.%_dry-basis, which is further upgraded to a hydrogen purity of 99.95% with a recovery of 90% via pressure swing adsorption. The process exhibits stable performance across scales, with Cold Gas Efficiency values around 60% and hydrogen yields close to 1 Nm³/kg_Biomass. The economic analysis highlights a decrease in the Levelized Cost of Hydrogen (LCOH) from 41.3 €/kg at 100 kWth to 6.8 €/kg at 10 MWth. These results indicate that SEG represents a promising pathway for low-carbon hydrogen production, while enabling the valorisation of biogenic residues within a sustainable energy framework. Full article

Understanding the carbon emission characteristics of fused filament fabrication (FFF) is important for the development of more sustainable additive manufacturing practices. This study presents a framework for quantifying, modelling, and optimizing the carbon emissions of FFF-printed specimens of carbon-reinforced Polyethylene Terephthalate Glycol (PETG-CF) composite. Carbon emissions were assessed within a cradle-to-gate system boundary by considering material consumption and electrical energy usage during fabrication. The influence of print speed, raster angle, layer height, infill density and infill pattern on carbon emissions were experimentally investigated. Response Surface Methodology (RSM) was utilized to formulate a predictive carbon emission model, while analysis of variance was applied to assess the significance of the process parameters. The findings revealed that infill density, infill pattern, layer height, and raster angle significantly affected carbon emissions, while print speed showed a comparatively lower influence. Contour plot analysis was used to visualize parameter interactions and identify low-emission regions. RSM-based optimization predicted a minimum carbon emission of 0.0732 kgCO₂eq at a print speed of 220 mm/s, layer height of 0.12 mm, infill density of 50%, raster angle of 0°, and rectilinear infill pattern. The proposed framework presents a practical strategy for integrating carbon emissions for a sustainable FFF process. Full article

The rapid global expansion of data center infrastructure has prompted substantial clean technology research on energy, water, and carbon impacts, while the acoustic health dimension of these facilities remains virtually unstudied. Existing occupational and environmental noise assessments rely on A-weighted (dBA) metrics, which apply more than 26 decibels (dB) of attenuation at 63 hertz (Hz) and exceed 50 dB at infrasound frequencies, sharply discounting their sensitivity to infrasound and low-frequency noise (ILFN) generated by data center cooling fans, heating, ventilation, and air conditioning (HVAC) systems, backup generators, and power transformers. This narrative review synthesizes evidence from established ILFN health research alongside the emerging data center acoustics literature, identifying a consequential gap: no published study has measured the ILFN spectrum of an operational data center, nor examined health outcomes in workers or surrounding communities with respect to sub-audible acoustic exposure. Evidence from wind turbine, industrial, and laboratory contexts documents non-auditory ILFN pathways, including sleep disturbance, cardiovascular stress responses, cognitive impairment, and audiovestibular symptoms—effects that operate below the auditory threshold and are substantially undercounted by standard dBA monitoring. A prioritized research agenda is proposed, beginning with G-weighted and flat-response ILFN characterization of operational data centers across at least 1–200 Hz—a prerequisite for evidence-based acoustic design standards and health-protective infrastructure development consistent with clean technology principles. Full article

This study evaluates, from energy, exergy, exergo-sustainability, and environmental perspectives, two combined-cycle configurations based on a supercritical CO₂ Brayton cycle coupled to an ORC: a simple reheat configuration (S-CO₂-ORC) and a recompression-reheat configuration (SRC-CO₂-ORC). Both were assessed under two thermal sources: concentrated solar power (CSP) and a hybrid biomass-CSP source using oil palm residues. Sizing was based on the cooling demand of a 130-home residential complex in Barranquilla, estimated at 152 kW through hourly simulation. The SRC-CO₂-ORC configuration delivered the best energy performance, reaching 138.38 kW and 55.34% with CSP and up to 157.28 kW and 57.66% under hybrid operation. The highest irreversibilities were concentrated in the solar field and receiver, while the thermal sources contributed more than 85% of the total carbon footprint. The lowest life-cycle impact corresponded to the SRC-CO₂-ORC-Solar configuration, at 0.0117 kg CO₂-eq/kWh, against 0.0194 kg CO₂-eq/kWh for the S-CO₂-ORC-Hybrid case. The results confirm the technical feasibility of these configurations for residential applications and reveal a clear trade-off between thermodynamic performance and minimum carbon footprint. Full article

This study quantified environmental impacts of circularity strategies in the manufacturing industry, focusing on maintenance-driven product lifetime extension (PLE) using Life Cycle Assessment (LCA). The analyzed case builds on earlier work, which showed that the product’s lifetime was shorter than the industry average lifetime and that the use phase was the dominant contributor to overall environmental impacts, identifying it as a key area for improvement. A computational code was developed to model maintenance-driven lifetime extension scenarios and to calculate selected total and normalized environmental impacts for the studied industrial process equipment. The model assumes maintenance-related impacts are smaller than the impacts avoided through reduced new production. Results show that while total impacts increase with longer use, normalized impacts per unit of production and per year of service life decrease by 58%, improving resource efficiency. Maintenance-driven PLE supports circular economy (CE) strategies by slowing material flows and extending product use. The findings highlight the importance of incorporating maintenance into circularity frameworks and life cycle-based decision-making. Full article

This study proposes a hydrogen-powered industrial ride-on scrubber (IRoS) investigated by using in situ and on-board H₂ production. Technological and financial calculations involving conventional liquefied petroleum gas (LPG), an electric battery, and a hydrogen-powered system in IRoS are discussed. Energy consumption, operational costs, financial aspects and environmental impacts are also discussed. Investment payback analyses to replace an LPG machine are discussed. For 10 years, the highest operational costs and downtime costs are of the LPG-powered scrubber (USD ~187k). The two other systems are substantially lower, i.e., ~4% and 7%. CO₂ emissions of the three examined scrubbers ranged between 162 and 194, 10 and 13, and 5 and 9 tCO₂, respectively. Gravimetric energy density (GED) reveals that the LPG-powered system is ~2× and 10× higher than the battery- and H₂-powered systems, respectively. Adequate modulation and control of the produced H₂ volume in Al hydrolysis are keys to success in the H₂-powered scrubber project. For this purpose, three aspects are important: i. adequate selection of Al-based alloy or mixture powders, ii. the nature and concentration of alkali solution and iii. the quantity of solid (Al-based alloy or mixture powders) per volume of alkali (liquid), designated as S/L ratio. Full article

Reliable experimental platforms are essential for lithium-ion (Li-Ion) battery characterization, equivalent circuit model (ECM) identification, and state-of-charge (SOC) estimator validation. However, access to commercial battery cyclers and high-end instrumentation can be limited in academic and applied research environments, which motivates the development of low-cost and reproducible test benches. This work presents the development and validation of a low-cost experimental platform for Li-Ion battery characterization, SOC-dependent ECM identification, voltage model validation, and SOC estimator assessment. The proposed platform integrates constant-current–constant-voltage (CC-CV) charging, a controlled-current electronic load implemented on a printed circuit board (PCB), ESP32-based embedded acquisition, and MATLAB-based data processing. A Samsung INR18650-35E cell was characterized through full-discharge tests at different C-rates, pulse discharge tests (PDTs), and dynamic current profiles. The measured capacity at 0.2C was 3345.1 mAh, showing close agreement with the manufacturer-reported minimum nominal capacity of 3350 mAh. First- and second-order Thévenin ECMs were identified from PDT data, parameterized as SOC-dependent models, and validated under Scaled Dynamic Stress Test (DST) and Modified Pulsed Dynamic Stress Test (P-DST) profiles. The second-order ECM identified from the most complete PDT dataset achieved voltage RMSE values of 23.24 mV and 12.14 mV under the DST and P-DST profiles, respectively. The platform was further used to evaluate SOC estimators based on extended Kalman filters (EKF) and a hybrid Extended Kalman Filter-Artificial Neural Network (EKF-ANN) residual correction method. The EKF based on the second-order ECM achieved SOC RMSE values of $0.5088\%$ and $1.0890\%$ under the complete dynamic profiles, while the hybrid EKF-ANN reduced the RMSE to $0.2276\%$ and $0.2788\%$ over the dynamic test blocks. These results show that the proposed platform provides an accessible experimental framework for connecting battery testing, ECM identification, voltage validation, and BMS-oriented SOC estimator evaluation within a single reproducible workflow. Full article

Aerobic composting is an important pathway for the resource utilization of agricultural waste. However, nitrogen loss during composting not only reduces the nutrient value of the final product but also causes environmental burdens, particularly through ammonia (NH₃) volatilization and nitrous oxide (N₂O) emissions. The objective of this review is to systematically summarize the sources, pathways, and mechanisms of nitrogen loss during aerobic composting of agricultural waste and to evaluate multi-scale control strategies for enhancing nitrogen retention and mitigating environmental emissions. This review addresses an important gap by integrating the sources, pathways, and mechanisms of nitrogen loss with practical mitigation strategies across the feedstock, in-process, post-treatment, system design, and macro scales. The synthesis indicates that the major nitrogen loss routes during aerobic composting include NH₃ volatilization, N₂O emissions, and nitrate leaching. From a multiscale perspective, the review synthesizes control strategies spanning feedstock pretreatment, including optimization of carbon-to-nitrogen (C/N) ratio, adsorbent amendment, and microbial inoculation; in-process regulation, including aeration, moisture, temperature, pH; and post-treatment approaches for nitrogen stabilization and resource recovery. The supporting roles of reactor innovation, intelligent process control, and policy and regulatory measures are also discussed. Finally, current bottlenecks and future research directions are summarized from environmental and economic perspectives, with particular emphasis on interdisciplinary integration and technological innovation to enhance nitrogen retention during composting. Full article

Power-to-Ammonia-to-Power (P2A2P) systems in hot-arid MENA climates reject waste heat through Recuperated Organic Rankine Cycles (RORCs) whose condensation temperature tracks ambient conditions across annual swings exceeding 35 K. Standard exergoenvironmental assessments evaluate priorities at a single dead-state temperature, an assumption this study terms the Static $T_0$ Fallacy. A four-way advanced exergy decomposition is combined with an off-design model (Stodola’s ellipse, constant-$UA$ scaling) to sweep the dead-state temperature from ${5 }^{\circ }$C to ${40 }^{\circ }$C. At $T_0={20 }^{\circ }$C, 95.8% of total exergy destruction is endogenous, confirming weak inter-component coupling. The condenser carries the largest avoidable environmental impact rate (4.02 mPts/h, 74% of the system total). At $T_0={37.4 }^{\circ }$C, the recuperator undergoes a priority inversion from destruction-dominated ($f_b=14.7\%$) to fully capital-dominated ($f_b=100\%$). Ammonia’s wet-fluid thermodynamic coupling eliminates the recuperator’s duty as the condensation temperature approaches the cold-side outlet constraint. The recuperator’s avoidable environmental impact rate drops by 100% relative to the standard assessment, while the condenser’s rises by 49%. This inversion mechanism is fluid-specific: the ammonia recuperator’s endogenous fraction reaches 99.5% at $T_0={20 }^{\circ }$C. The toluene recuperator, swept at its own independently optimised operating point, has an endogenous fraction between 59.08% and 82.31% over the same range. For P2A2P installations where the annual ambient swing exceeds 15 K, exergoenvironmental analysis should be performed at both design-season and summer-peak dead-state temperatures, with the summer-peak result governing capital allocation. Full article

Managing polymer waste, primarily polyolefins—low- and high-density polyethylene and polypropylene—is a critical challenge in the transition to a low-carbon, circular economy. Traditional approaches (landfilling and incineration) are inconsistent with sustainable development principles and increasingly stringent extended producer responsibility regulations, while chemical recycling, particularly catalytic pyrolysis, is considered a key technology for returning hydrocarbon feedstocks to the production cycle. This mini-review systematizes and analyzes current advances in the catalytic pyrolysis of polyethylene and polypropylene. An algorithm for selecting a recycling route for polyolefin-containing waste based on its composition, degree of degradation, and the presence of hazardous additives is proposed. Existing and planned industrial projects in the field of chemical recycling of polyolefins are assessed, and challenges and prospects for technology commercialization are outlined. It is demonstrated that catalytic pyrolysis has the potential to become a key element of a circular economy for plastics, ensuring decarbonization and resource conservation with further optimization of catalysts and process flowsheets. Full article

Hydrogen-based technologies are widely considered promising pathways for decarbonizing power generation and industrial energy systems; however, their overall sustainability depends strongly on both production routes and conversion efficiencies. This study presents a comparative energy and exergy analysis of hydrogen-based decarbonization pathways under a consistent 1 MW net electrical output boundary, including natural gas combustion (S0), grey hydrogen combustion (S1), grey hydrogen fuel cell (S2), green hydrogen combustion (S3), and green hydrogen fuel cell (S4) systems. The results indicate that combustion-based pathways (S0, S1, and S3) exhibit relatively low energy efficiencies of approximately 30–40% and exergy efficiencies of 25–40%, accompanied by high exergy destruction levels generally exceeding 60%. In contrast, fuel cell-based configurations (S2 and S4) demonstrate improved conversion-stage thermodynamic performance, achieving energy efficiencies of 50–60% and exergy efficiencies of 45–65%, while reducing exergy destruction due to electrochemical conversion and lower irreversibilities. A detailed comparison shows that the natural gas reference system reaches an exergy efficiency of 33.7%, whereas the hydrogen fuel cell system achieves 46.5%, corresponding to approximately 42% lower exergy destruction and about 36% reduced fuel input. From an environmental perspective, the simplified carbon assessment indicates that natural gas combustion generates approximately 577 kg CO₂/h. Grey hydrogen pathways remain associated with substantial upstream emissions, generating approximately 857 kg CO₂/h for grey hydrogen combustion and 545 kg CO₂/h for grey hydrogen fuel cell operation under the 1 MW net electrical output basis. In contrast, green hydrogen-based pathways are assumed to have near-zero direct/upstream operational CO₂ emissions under renewable-powered production assumptions. Overall, the findings show that hydrogen use alone does not guarantee decarbonization; rather, both the hydrogen production route and the final conversion technology must be considered to achieve thermodynamically efficient and low-carbon power generation. Full article

The article presents the results of the development of multicomponent adsorption materials based on industrial waste sludge from the water treatment plant of a thermal power plant. Activation of the sludge at 1000 °C makes it possible to obtain a porous matrix. It has been experimentally established that compositions with 50% activated sludge content in combination with oxides of Zn, Fe, Mn, Cu and NaOH have an optimal sorption capacity with respect to hydrogen sulfide. Kinetic studies have shown that the optimal contact time of the adsorbent with the adsorbate is 15–20 min, and the operating temperature should not exceed 300 K. The calculated thermodynamic parameters confirm the exothermic chemical mechanism of sorption. The materials have the ability to regenerate and display a color change upon contact with hydrogen sulfide. With respect to mercaptan sulfur, the maximum capacity was achieved for the sorption composition with 74.7% ZnO content. The logarithmic dependence of the mercaptan sulfur capacity on the percentage of zinc oxide in the composition has also been established. The environmental significance of the work lies in the utilization of large-tonnage waste and the absence of liquid effluents during regeneration. The proposed materials show promise as potentially cost-effective alternatives for gas purification, though comprehensive economic analysis remains the subject of future work. Full article

Global decarbonization represents one of the defining challenges of the 21st century. Geothermal energy offers a robust alternative for reducing fossil fuel dependency for both residential and industrial heating and cooling. While shallow geothermal systems are versatile and high-performing, comprehensive Life Cycle Assessments (LCA) remain scarce in the literature. This study evaluates the environmental impact of the manufacturing and installation processes of next-generation coaxial probes featuring a galvanized steel outer tube and an internal polyethylene pipe. The LCA identifies material composition as the primary environmental driver: steel production accounts for 41% of the total impact, while the hot-dip galvanization process contributes 30%, significantly affecting the “climate change” and the “resource use” categories. A comparative LCA with conventional double U-tube installations shows similar overall environmental impacts. A sensitivity analysis on the coaxial probes was conducted to explore potential mitigation strategies aimed at reducing the associated environmental impacts, providing indications for sustainable eco-design. The LCA results demonstrate that optimizing the design, specifically by reducing the steel quantity in the coaxial outer tube and avoiding the zinc coating process, results in a 34% reduction in total environmental impact, confirming that LCA is a fundamental tool for supporting the environmental sustainability of developing technologies. Full article

Transport decarbonization requires infrastructure that can use time-resolved carbon information without overstating the representativeness of short proof-of-method runs. This study introduces Adaptive Energy Stations (AESs), multi-fuel transport-energy nodes that integrate marginal grid-emission signals, fuel life-cycle carbon intensities, wholesale electricity prices, and vehicle operating constraints into a station-level dispatch optimization. The implemented case is a one-week winter proof-of-method for CAISO/CAISO_NORTH using 168 hourly service events over 1–8 January 2026 Pacific time, archived WattTime marginal operating emissions, CAISO locational marginal prices, eGRID CAMX annual-average factors, and declared vehicle and fuel-pathway parameters. In the audited CAISO scenario, the attached dispatch outputs report a reduction from 181.76 to 123.38 g CO₂e/km relative to the specified static baseline, corresponding to a 32.12% reduction for the one-week winter service-event stream. The populated dispatch trace shows that the carbon-priority AES plug-in hybrid electric vehicle (PHEV) run selected cellulosic E85 for all 168 events and selected no electric events; this result is interpreted as an operational scenario result for the archived week, not as an annual fleet-average, smart-charging benefit, or deployment forecast. The revised analysis explicitly separates implemented CAISO evidence from ERCOT, MISO-MROW, and ISO–NE extension sensitivities, which remain hypothetical until equivalent marginal-emissions, price, and service-event data are supplied. Battery-production amortization is treated as a separate sensitivity because it can change battery electric vehicle (BEV)–cellulosic E85 equivalence conclusions: at 50–100 kg CO₂e/kWh over 240,000 km, a 75 kWh BEV pack contributes 15.6–31.3 g CO₂e/km and a 14 kWh PHEV pack contributes 2.9–5.8 g CO₂e/km. Practical-equivalence claims are therefore conditional on the declared boundary, equivalence margin, and production-emissions treatment. Full deployment requires validated marginal-emission access, transparent dispatch-audit outputs, supply-chain verification, user-behavior characterization, cost sensitivity analysis, and cybersecurity safeguards. Full article

Red mud is a waste byproduct of alumina production. Its release into the environment poses risks, highlighting the need for strategies to limit pollution. Using red mud as a filler in polymer-matrix composites can reduce the leaching of heavy metals and metalloids. We fabricated composites with high red mud content (up to 60 wt.%) using two particle fractions (<125 μm and <500 μm). The study examined how filler concentration and particle size affected the composites’ microstructure and mechanical properties. Results showed that composites with smaller particles had better encapsulation and enhanced structural qualities, such as reduced porosity and fewer cracks. Among four filler mass loadings (20, 30, 40, and 60 wt.%), composites with 40 and 60 wt.% red mud exhibited greater epoxy penetration into agglomerates and partial deagglomeration, resulting in small, uniformly dispersed red mud particles within the matrix. Calorimetry analysis demonstrated that increasing the red mud concentration slows the curing process: for composites with 20 wt.% red mud, the curing time is approximately 10 h, whereas for composites with 60 wt.%, approximately 35 h. We performed a thorough environmental safety evaluation of high-loaded red mud–epoxy composites in accordance with the standard AS 4439.3:2019. The tests showed that epoxy resin significantly reduces the levels of potentially hazardous elements, such as Na and Al, in the leachates, demonstrating the safety of the composites. Composites with 40 wt.% red mud (particle size < 125 μm) showed the most effective epoxy impregnation into red mud agglomerates and demonstrated the best encapsulation behaviour, releasing the least amount of metals compared to red mud during both 20 h and 4-week, long-term leaching tests. Full article