| Abstract Scope |
Bauxite residue (red mud) is an abundant secondary resource for rare earth elements (REEs), yet the economic feasibility of their recovery remains uncertain. This study presents a techno-economic assessment of an integrated hydrometallurgical and electrochemical process for REE recovery from red mud. The proposed flowsheet includes leaching, impurity removal, rare earth concentration, electrochemical recovery, electrolyte regeneration, and reagent recycling. Material and energy balances are developed using experimental and literature data to estimate capital and operating costs. Sensitivity analyses evaluate the impacts of leaching efficiency, Faradaic efficiency, electricity price, reagent recycling, and plant capacity on the minimum selling price of recovered rare earth oxides. The model analyzes benefits of coproduct recovery and renewable electricity integration. Results identify key economic drivers and process performance targets required for commercial viability while reducing chemical consumption and waste generation. This framework provides quantitative guidance for scaling sustainable electrochemical recovery of critical minerals from industrial residues. |