| 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. |