Bauxite ore is the main raw material for aluminum production it is converted into alumina Al2O3 to obtain a proper charge material for aluminum production in Hall Heroult process Bayer process is the main commercial alumina production method in which bauxite ore is first digested by NaOH at moderate hydrothermal conditions followed by aluminum hydroxide Al OH 3 precipitation
·During acid leaching of bauxite residue red mud the increase in dissolution of rare earth elements REEs is associated with an increase in iron dissolution which poses problems in the downstream processing Therefore it would be beneficial to remove iron from bauxite residue by smelting reduction The slag generated in the smelting reduction process
·This process completes the iron metallization in bauxite residue before the smelting process avoiding the addition of carbon during smelting and thus preventing the formation of titanium carbonitride Additionally the pre reduction process can regulate the FeO content in the smelted titanium slag facilitating the separation of pig iron from
·However the high temperature reduction smelting and alkaline leaching process is a feasible method to recover iron and alumina from iron rich bauxite and red mud This chapter intends to provide the reader an overview on comprehensive utilization technology of the low grade iron rich bauxite and Bayer red mud sources
·High iron bauxite IRB red mud RM and fly ash FA are resources rich in iron and alumina yet there are no effective methods of recovering and utilizing them In this paper a new reduction smelting technology for the extraction of iron and alumina from IRB RM and FA is proposed based on the technology platform of Slag Metallurgy Mineral Recycling
·Therefore it would be beneficial to remove iron from bauxite residue by smelting reduction The slag generated in the smelting reduction process could then be further processed for recovery of REEs
·This flux regeneration step can potentially be implemented into the bauxite residue smelting process by performing in situ desulfation during flux preheating in previously reported pilot scale implementations of bauxite residue smelting the fluxes were typically preheated in an electric arc furnace ladle to the smelting temperature and then
·Commercial grades of bauxite are normally processed by a chemical process known as the Bayer Process discussed briefly in this chapter and in detailed discussions of the steps in that process in later chapters in this book The Bayer Process produces the purified alumina that is the raw material for the aluminum smelting process
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