| Abstract Scope |
Red mud, a caustic byproduct of the Bayer process, is a major industrial waste stream rich in critical minerals such as iron, titanium, gallium, and rare earth elements (REEs). Conventional extraction methods are often energy-intensive and environmentally harmful, limiting large-scale valorization. This work proposes a low-cost, low-carbon, and near-zero-waste approach for red mud processing using integrated hydrometallurgical and electrohydrometallurgical techniques. Selective leaching and electrochemical methods are employed to recover valuable metals while minimizing chemical use and eliminating secondary waste generation. We incorporate life cycle assessment (LCA) and techno-economic analysis (TEA) to evaluate the environmental and economic performance of the proposed processes. Results show that red mud can be transformed from an environmental liability into a viable secondary resource, supporting sustainable mining and critical material supply. This approach contributes to a circular economy model and aligns with international goals for waste minimization, decarbonization, and resource efficiency in extractive industries. |