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The recovery of major components of bauxite residue by carbothermic reduction at 1550–1750 °C and subsequent slag leaching in a Na3CO3(aq) solution is studied. Iron recovers primarily to pig-iron and lime is added to tune the calcium aluminate slags towards the highly leachable mayenite phase. The concentration of aluminum in the leachate correlates well with the occurrence of mayenite and aluminum recoveries up to 50–60% are observed. However, slags with low CaO additions are vulnerable to gehlenite formation and display reduced leachabilities. Formation of an inhibiting layer of CaCO3(s) on the reaction surface of calcium-aluminate particles during leaching and immobilization of aluminum in CaTiO3(s) are also suggested to play important roles in limiting the aluminum leachability. Costs related to post-processing may be reduced by achieving disintegrating slags, a behavior which is observed for slags holding high γ- to β-Ca2SiO4 ratios. The disintegration is caused by the large volume expansion associated with the β-to-γ transformation and as such, various factors that are known to stabilize the β-polymorph are discussed. Graphical Abstract

The sludge generated by wet scrubbing the off-gas from a silicomanganese plant in Norway represents a significant loss in silicon and manganese values. This work seeks to extract these values in the production of ferroalloys and slags that can be utilized by alternative industries. Carbothermic smelting the sludge together with iron or iron scraps at 1600 °C produced FeSiMn alloys consisting of 57–64 wt.% Mn, 16–22 wt.% Si and 18–25 wt.% Fe. The low level of phosphorus in the sludge allowed for beneficial phosphorus concentrations as low as 500 ppmw in the metal alloys. The addition of lime to the material mix resulted in increased evaporation of alkalis, capture of sulfur in the slags as calcium sulfides and slag compositions similar to conventional steel-making slags that can be recycled accordingly. Graphical Abstract