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Meeting 2025 TMS Annual Meeting & Exhibition
Symposium Bauxite Residue Valorization and Best Practices
Presentation Title Hydrogen-Driven Sustainable Multi-Metal Recovery Approaches for Bauxite Residue: A Comparative Analysis
Author(s) Ganesh Pilla, Tobias Hertel, Yiannis Pontikes
On-Site Speaker (Planned) Ganesh Pilla
Abstract Scope Bauxite residue (BR), a byproduct of the Bayer process, offers potential for metal extraction. This study evaluated three recovery methods: (a) H2 reduction (600 °C) with water leaching and wet magnetic separation, (b) H2 reduction (900 °C) with water leaching and wet magnetic separation, and (c) H2 reduction (600 °C) followed by smelting with biocarbon. Method (a) achieved 74.4% Fe recovery (63% magnetite), 84.6% Al, and 91.6% Na. Method (b) showed 88.1% Fe recovery (70% pure Fe), 94.5% Al, and 92.6% Na. Method (c) reached 99.3% Fe recovery (96% pig iron), 80% Al, and 95.6% Na. Impurities and poor particle liberation limit Fe grades in (a) and (b), while (c) is energy-intensive. These methods support sustainable BR valorization, recovering Fe, Al, Na, and enriching non-magnetic fractions for further extraction and use in building materials.
Proceedings Inclusion? Planned: TMS Journal: Journal of Sustainable Metallurgy

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Linear Programming-Based Approach for Creating Cements from Bauxite Residue
Activated Bauxite Residue Application in Wastewater Treatment
Assessing the Carbonation Potential of De-alkalized Bauxite Residue Using Different Carbonation Methods
Assessment of High Temperature Valorisation Routes for Bauxite Residue towards Cementitious Binders: A Case Study on Vitrification
BR Valorisation: Can We See It Differently?
Developments in EGA’s Bauxite Residue Roadmap
Hydrogen-Driven Sustainable Multi-Metal Recovery Approaches for Bauxite Residue: A Comparative Analysis
Impact of Chemical Admixtures on the Setting Time and Freeze-Thaw Resistance of Bauxite Residue-Based Geopolymer
Innovative Hydrometallurgical Methods for Extracting Metallic Oxides from Bauxite Residue
Mineralogy Prediction for Iron-Rich Sulfo-Aluminate Cements Made from Elevated Contents of Bauxite Residue
Optimising Bauxite Residue for Use as a Soil Component
Pelletization and Hydrogen Reduction of Bauxite Residue in Pilot Scale
Processing Routes of Bauxite Residue And Its Valorisation Potential: Various Case Studies Demonstrated at Pilot Scale
Recovery of Titanium from Production Residues via Physical and Chemical Processing
Red Mud to Produce Sustainable Iron and Steel - A Thermodynamic Analysis
Synergistic Pyrolysis with Refuse-Derived Fuel (RDF) Can Neutralize Bauxite Residue (BR)
Towards Scalable Autoclaved Masonry Units: How Bauxite Residue Feedstock Characteristics Impact Performance
Utilizing Mining Tailings for Sustainable Steel and Rare Earth Element Recovery

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