The Enexal Bauxite Residue Treatment Process: Industrial Scale Pilot Plant Results

Balomnenos, Efhtymios; Kastritis, Dimitrios; Panias, Dimitrios; Paspaliaris, Ioannis; Boufounos, Dimitrios

doi:10.1002/9781118888438.ch25

Cited by 11 publications

(14 citation statements)

References 5 publications

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“…Obviously, the commitment of resources in the second trajectory is much higher, although it could be the way forward. An example of that approach is the ENEXAL bauxite residue treatment process (Balomenos et al, 2014;Balomenos et al, 2013). Through electric arc furnace carbothermic smelting, bauxite residue is fully converted into two marketable products: pig iron and mineral wool.…”

Section: Towards Zero-waste Valorisation Of Bauxite Residuementioning

confidence: 99%

“…In this approach, a great amount of work already done in the early 1960s by the US Bureau of Mines on clays, could be now extrapolated both on bauxite residue and iron-lean slags (e.g. from the ENEXAL process) (Balomenos et al, 2014;Balomenos et al, 2013). The processes investigated on clays were based on HNO 3 , sulphurous acid, HCl-isopropyl ether extraction, lime-soda with wet or dry grind option, H 2 SO 4 -electrolytic iron removal, H 2 SO 4 -chemical iron removal and potassium alum (Peters et al, 1967).…”

Section: Towards Zero-waste Valorisation Of Bauxite Residuementioning

confidence: 99%

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Towards zero-waste valorisation of rare-earth-containing industrial process residues: a critical review

Binnemans

Jones

Blanpain

et al. 2015

Journal of Cleaner Production

516

282

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The supply risk for some critical rare-earth elements (REEs), which are instrumental in many cleantech applications, has sparked the development of innovative recycling schemes for Endof-Life fluorescent lamps, permanent magnets and nickel metal hydride batteries. These waste fractions represent relatively small volumes, albeit with relatively high rare-earth contents.Nevertheless, rare earths are also present in lower concentrations in a multitude of industrial process residues, such as phosphogypsum, bauxite residue (red mud), mine tailings, metallurgical slags, coal ash, incinerator ash and waste water streams. This review discusses the possibilities to recover rare earths from these "secondary resources", which have in common that they contain only low concentrations of rare-earth elements, but are available in very large volumes and could provide significant amounts of rare earths. The success rate is set to increase if the rare-earth recovery from these industrial waste streams is part of a comprehensive, zero-waste, "product-centric" valorisation scheme, in which applications are found for the residual fractions that are obtained after removal of not only the rare earths but also other valuable (base) metals.

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Section: Towards Zero-waste Valorisation Of Bauxite Residuementioning

confidence: 99%

Section: Towards Zero-waste Valorisation Of Bauxite Residuementioning

confidence: 99%

Towards zero-waste valorisation of rare-earth-containing industrial process residues: a critical review

Binnemans

Jones

Blanpain

et al. 2015

Journal of Cleaner Production

516

282

View full text Add to dashboard Cite

show abstract

“…The basic component of red mud is iron, which content in it can reach 40% or more. Attempts to produce iron from red mud using methods of reduction smelting [3][4][5], leaching [6], and direct separation in a high-intensity magnetic field [7] are well known. Magnetic separation after solid-phase carbothermic reduction of red mud can be a more promising method of iron extraction.…”

Section: Kne Materials Sciencementioning

confidence: 99%

The Research of the Carbothermic Solid–Phase Red Mud Reduction Process in the Presence of Sodium Sulphate

Zinoveev

Grudinsky

Semenov

et al. 2020

Kms

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Russia has accumulated about 600 million tons of the red mud that is alumina production waste generated by Bayer method, but currently only a small amount of the total accumulated red mud is recycled. Solid–phase carbothermic reduction of red mud in the presence of sodium salts with magnetic separation can be a promising method for iron extraction. In this paper, the effect of the addition of sodium sulphate on the reduction of iron–containing phases and the growth of iron grains during solid–phase carbothermic reduction of red mud was investigated. The results show that 10% sodium sulphate additive significantly accelerate the growth of reduced iron grains, but decrease the degree of its reduction at temperatures above 1100∘C. The explanation of mechanism of sodium sulphate effect on the iron grain growth was proposed. Optimization of sodium sulphate amount, temperature and holding time can lead the development of effective technology of iron extraction from red mud by solid–phase carbothermic reduction. Keywords: red mud, solid–phase carbothermic reduction, sodium sulphate

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“…Thus, CRM recovery is in particular financially interesting under the frame of zero-waste overall reuse of bauxite residues (see above), or even on itself depending on the market price of recovered CRM. 113,114 The reduction of long-term liabilities can be quantified in monetary terms as well. In addition to direct monetary benefits, improvements in environmental protection and health can be expected due to emission reduction on the disposal sites, but as well savings in emissions from conventional primary mining of CRM.…”

Section: Direct and Indirect Benefits Of Crm Recovery From Bauxite Rementioning

confidence: 99%

Re‐using bauxite residues: benefits beyond (critical raw) material recovery

Ujaczki

Feigl

Molnár

et al. 2018

J of Chemical Tech & Biotech

110

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Since the world economy has been confronted with an increasing risk of supply shortages of critical raw materials (CRMs), there has been a major interest in identifying alternative secondary sources of CRMs. Bauxite residues from alumina production are available at a multi‐million tonnes scale worldwide. So far, attempts have been made to find alternative re‐use applications for bauxite residues, for instance in cement / pig iron production. However, bauxite residues also constitute an untapped secondary source of CRMs. Depending on their geological origin and processing protocol, bauxite residues can contain considerable amounts of valuable elements. The obvious primary consideration for CRM recovery from such residues is the economic value of the materials contained. However, there are further benefits from re‐use of bauxite residues in general, and from CRM recovery in particular. These go beyond monetary values (e.g. reduced investment / operational costs resulting from savings in disposal). For instance, benefits for the environment and health can be achieved by abatement of tailing storage as well as by reduction of emissions from conventional primary mining. Whereas certain tools (e.g. life‐cycle analysis) can be used to quantify the latter, other benefits (in particular sustained social and technological development) are harder to quantify. This review evaluates strategies of bauxite residue re‐use / recycling and identifies associated benefits beyond elemental recovery. Furthermore, methodologies to translate risks and benefits into quantifiable data are discussed. Ultimately, such quantitative data are a prerequisite for facilitating decision‐making regarding bauxite residue re‐use / recycling and a stepping stone towards developing a zero‐waste alumina production process. © 2018 The Authors. Journal of Chemical Technology & Biotechnology published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry.

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The Enexal Bauxite Residue Treatment Process: Industrial Scale Pilot Plant Results

Cited by 11 publications

References 5 publications

Towards zero-waste valorisation of rare-earth-containing industrial process residues: a critical review

Towards zero-waste valorisation of rare-earth-containing industrial process residues: a critical review

The Research of the Carbothermic Solid–Phase Red Mud Reduction Process in the Presence of Sodium Sulphate

Re‐using bauxite residues: benefits beyond (critical raw) material recovery

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