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An Efficient Process to Recover Iron from Bayer Red Mud

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Abstract

We have investigated Bayer red mud with a TFe content of 26.86% collected from the Pingguo area of China, and have found that iron is the key metal affecting the extraction of valuable components such as Sc, Ti, and Ga. Based on this, an efficient process of roasting with calcium salt and magnetic separation has been proposed to extract iron from the Bayer red mud. Coke, calcium chloride, and calcium hypochlorite were put into a resistance furnace for roasting, and iron was converted from low-intensity magnetic iron minerals to high-intensity magnetic iron minerals. Iron was recovered from the roasted ore by low-intensity magnetic separation after wet grinding. We found that calcium chloride and calcium hypochlorite can promote FeO to be reduced to Fe0 on the coke surface after FeCl3 is added, and that CaO produced by calcite decomposition can promote FeSiO3 to be reduced to Fe0, which significantly increases the content of metal iron in the roasted ore. An iron concentrate with a TFe content of 86.86% and an iron recovery of 91.48% was obtained. The main minerals in the iron concentrate were Fe0 and Fe3O4, which accounted for 58.78% and 20.37% of the total iron, respectively.

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Acknowledgements

This study was funded by the Sichuan Science and Technology Program (Grant Nos. 2022YFS0462, 2021YJ0057, and 2021YFG0268), the Project funded by China Postdoctoral Science Foundation (Grant No. 2014M560734), and Key Laboratory of Guangdong Provincial Key Laboratory of Radioactive and Rare Resource Utilization (Grant No. 2018B030322009).

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Authors and Affiliations

  1. Sichuan Provincial Engineering Lab of Nonmetallic Mineral Powder Modification and High-Value Utilization, Southwest University of Science and Technology, Mianyang, 621010, China

    Junhui Xiao, Nanlan Zhong, Deqiang Gao, Kai Zou & Zhen Wang

  2. Dongfang Boiler Group Co., Ltd., Zigong, 643001, China

    Junhui Xiao

  3. Institute of Multipurpose Utilization of Mineral Resources, Chinese Academy of Geological Sciences, Chengdu, 610041, China

    Junhui Xiao & Wenliang Xiong

  4. Guangdong Provincial Key Laboratory of Radioactive and Rare Resource Utilization, Guangdong Institute of Mineral Resources Application, Shaoguan, 512026, China

    Junhui Xiao & Wenxiao Huang

  5. Key Laboratory of Ministry of Education for Solid Waste Treatment and Resource Recycle, Southwest University of Science and Technology, Mianyang, 621010, China

    Junhui Xiao, Nanlan Zhong, Deqiang Gao, Kai Zou & Zhen Wang

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  1. Junhui Xiao
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Xiao, J., Zhong, N., Gao, D. et al. An Efficient Process to Recover Iron from Bayer Red Mud. JOM 74, 3172–3180 (2022). https://doi.org/10.1007/s11837-022-05373-2

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