| Abstract Scope |
Bauxite residue, or red mud, is one of the largest industrial waste streams, with billions of tonnes stored globally. Its high iron content limits further alumina recovery and reuse. We present a tunable and rapid process based on Flash Joule Heating with chlorination that removes up to 96% of iron and 94% of heavy metals, while retaining about 99% of the aluminum as a corundum-rich solid. The treated material can be sintered into high-strength ceramics comparable to commercial alumina. Kilogram-scale trials show that this technique significantly reduces energy use, cost, and carbon footprint compared to roasting, hydrometallurgy, or plasma methods. Flash Metals USA is now piloting the technology and evaluating applications in cement, ceramics, and alumina refining. This talk will highlight the laboratory development, scale-up progress, and potential for industrial adoption. |