Reductive Smelting of Red Mud for Iron Recovery

Kaußen, Frank; Friedrich, Bernd

doi:10.1002/cite.201500067

Cited by 43 publications

(27 citation statements)

References 13 publications

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“…After smelting, the entire melt is then poured into a steel Table 1. Apparently the metal phase can be described as typical pig iron, which is carbon saturated, rich in phosphor and has to be further treated and refined in a converter to produce steel [30]. For further processing, the slag phase is crushed and ground to grain size \125 µm, and entrapped metal droplets are removed by magnetic separation.…”

Section: Bayer Process With Alumina-enriched Slagmentioning

confidence: 99%

Methods for Alkaline Recovery of Aluminum from Bauxite Residue

Kaußen

Friedrich

2016

J. Sustain. Metall.

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Different ways for alkaline recovery of aluminum from bauxite residue are considered from the literature and examined in experiments. The advantages and disadvantages of a high-temperature digestion via Bayer process and soda-lime sintering process are elaborated and compared. As a hybrid process, bauxite residue undergoes a reductive smelting process with lime addition in an electric arc furnace in order to generate aluminaenriched slag. This slag is subsequently treated with highpressure caustic leaching at moderated (200-300 g/l) and high (572-762 g/l) sodium hydroxide concentrations. The aluminum extractions are related to phase transitions in mineralogy caused by the process parameter and are analyzed and proofed by x-ray diffraction. The results show moderate aluminum recoveries of 70 % in case of the use of Bayer process, extremely high aluminum extractions of 95 % in case of slag leaching at high NaOH concentrations, and even high recoveries of almost 90 % achieved by an optimized sinter process with subsequent leaching at 50°C with water. Special focus throughout all experiments is set on the dissolution of silicon as major impurity in the leachate.

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Section: Bayer Process With Alumina-enriched Slagmentioning

confidence: 99%

Methods for Alkaline Recovery of Aluminum from Bauxite Residue

Kaußen

Friedrich

2016

J. Sustain. Metall.

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“…A high content of alkali in RM (up to 12% Na2O [9]) leads to furnace lining destruction caused by high RM reactivity during the melting process. Despite this fact, most studies are devoted to the pyrometallurgical processing of the initial RM [10][11][12], because the alkali present in RM significantly reduces its melting point and improves the separation of slag and metal [13,14]. However, from our point of view, it would be more practical to regenerate the alkali for recirculation by autoclave leaching of bauxite [15,16], since during the smelting of red mud with high sodium content, the alkali goes into the gas phase, and its further regeneration is very difficult [17].…”

Section: Introductionmentioning

confidence: 99%

Reductive Smelting of Neutralized Red Mud for Iron Recovery and Produced Pig Iron for Heat-Resistant Castings

Valeev

Zinoveev

Kondratiev

et al. 2019

Metals

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The chemical and mineral composition of the red mud from the Ural Aluminum Plant were studied by XRF, XRD, and Mössbauer spectroscopy. Experiments on reductive smelting of red mud were carried out in a range of temperatures (1650–1750 °C) to recover iron from the aluminum production waste with maximum efficiency. It was found that it is possible to obtain pig iron with a high content of titanium, phosphorus, and vanadium, and low sulfur content. The efficiency of iron recovery at 1750 °C was found to be around 98%. Thermodynamic calculations were carried out to assist in finding the optimal conditions for the process (e.g., carbon content, furnace temperature, slag liquidus temperature). It was also found that the pig iron phase obtained at 1650 to 1700 °C is not separated from the slag phase into ingot compared with the sample obtained at 1750 °C. Pig iron obtained at 1750 °C can be used to produce molds for the steel-casting equipment.

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“…The pig iron produced from bauxite residue can be used in steel making [90]. A fundamental study on the smelting of bauxite residue at a laboratory scale was carried out by Kaußen and Friedrich [92]. They modeled the process using FactSage Ò and compared the modeling and experimental results.…”

Section: Reductive Smelting Of Bauxite Residue and Recovery Of Metalsmentioning

confidence: 99%

“…High concentrations of alumina in the bauxite residue increase the melting point as well as the viscosity of the slag during reductive smelting [92]. To compensate this alumina effect, large amounts of flux and/or high temperatures are required.…”

Section: Aluminum Recovery From Bauxite Residue In View Of Iron Titamentioning

confidence: 99%

Recovery of Rare Earths and Other Valuable Metals From Bauxite Residue (Red Mud): A Review

Gerven

Blanpain

Pontikes

et al. 2016

J. Sustain. Metall.

265

140

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The long-term storage of bauxite residue (red mud) is harmful to the environment and the tailing ponds also cover large areas. At the moment there is no largescale utilization of bauxite residue. However, some bauxite residues contain considerable concentrations of rare-earth elements (REEs) and the recovery of these REEs together with(out) other metals and utilization of the generated residue in other applications (e.g., building materials) can solve the storage problem of bauxite residue. This paper reviews the recovery of REEs, possibly alongside other valuable metals, from bauxite residue. REEs can be recovered from bauxite residue by direct leaching or by smelting followed by leaching. The main disadvantages of direct acid leaching are the consumption of large amounts of acid for neutralization, the handling of large volumes of effluents, and the difficulty in using the bauxite residue after leaching. Recovery of iron prior to leaching can improve the economics of the process. However, high alumina in the bauxite residue increases the flux and acid consumption. Therefore, alumina needs to be removed by alkali roasting prior to smelting in order to decrease the flux and acid consumption. The alkali roasting-smeltingleaching process allows recovery of aluminum, iron, titanium, and REEs from bauxite residue. The residue generated in this process can be used in building materials and cementitious binders. Other processes with commercial potential are the Orbite, the pressure leaching, and the acid baking processes.

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Reductive Smelting of Red Mud for Iron Recovery

Cited by 43 publications

References 13 publications

Methods for Alkaline Recovery of Aluminum from Bauxite Residue

Methods for Alkaline Recovery of Aluminum from Bauxite Residue

Reductive Smelting of Neutralized Red Mud for Iron Recovery and Produced Pig Iron for Heat-Resistant Castings

Recovery of Rare Earths and Other Valuable Metals From Bauxite Residue (Red Mud): A Review

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