Bauxite residue (BR), also known as red mud, is a byproduct of the alumina production using the Bayer process. This material is not used to make iron or other iron-containing products worldwide, owing to its high content of sodium oxide and other impurities. In this study, we investigated the hydrochemical conversion of goethite (FeOOH) to magnetite (Fe₃O₄) in high-iron BR from the Friguia alumina refinery (Guinea) by Fe²⁺ ions in highly concentrated alkaline media. The simultaneous extraction of Al and Na made it possible to obtain a product containing more than 96% Fe₃O₄. The results show that the magnetization of Al-goethite and Al-hematite accelerates the dissolution of the Al from the iron mineral solid matrix and from the desilication product (DSP). After ferrous sulfate (FeSO₄·7H₂O) was added directly at an FeO:Fe₂O₃ molar ratio of 1:1 at 120 °C for 150 min in solution with the 360 g L⁻¹ Na₂O concentration, the alumina extraction ratio reached 96.27% for the coarse bauxite residue size fraction (Sands) and 87.06% for fine BR obtained from red mud. The grade of iron (total iron in the form of iron elements) in the residue can be increased to 69.55% for sands and 58.31% for BR. The solid residues obtained after leaching were studied by XRD, XRF, TG-DTA, VSM, Mössbauer spectroscopy, and SEM to evaluate the conversion and leaching mechanisms, as well as the recovery ratio of Al from various minerals. The iron-rich residues can be used in the steel industry or as a pigment.

Bauxite residue, known as “red mud,” is a potential raw material for extracting rare-earth elements (REEs). The main REEs (Sc, Y, La, Ce, Nd, Nb, and Sm) from the raw bauxite are concentrated in RM after the Bayer leaching process. The earlier worldwide studies were focused on the scandium (Sc) extraction from RM by concentrated acids to enhance the extraction degree. This leads to the dissolution of major oxides (Fe₂O₃ and Al₂O₃) from RM. This article studies the possibility of selective Sc extraction from alkali fusion red mud (RMF) by diluted nitric acid (HNO₃) leaching at pH ≥ 2 to prevent co-dissolution of Fe₂O₃. RMF samples were analyzed by X-ray fluorescence spectrometry (XRF), X-ray diffraction (XRD), electron probe microanalysis (EPMA), and inductively coupled plasma mass spectrometry (ICP-MS). It was revealed that Sc concentration in RMF can reach up to 140–150 mg kg⁻¹. Sc extraction was 71.2% at RMF leaching by HNO₃ at pH 2 and 80 °C during 90 min. The leaching solution contained 8 mg L⁻¹ Sc and a high amount of other REEs in the presence of relatively low concentrations of impurity elements such as Fe, Al, Ti, Ca, etc. The kinetic analysis of experimental data by the shrinking core model showed that Sc leaching process is limited by the interfacial diffusion and the diffusion through the product layer. The apparent activation energy (E_a) was 19.5 kJ/mol. The linear dependence of Sc extraction on magnesium (Mg) extraction was revealed. According to EPMA of RMF, Sc is associated with iron minerals rather than Mg. This allows us to conclude that Mg acts as a leaching agent for the extraction of Sc presented in the RMF in an ion-exchangeable phase.

The processing of refractory gold-containing concentrates by hydrometallurgical methods is becoming increasingly important due to the depletion of rich and easily extracted mineral resources, as well as due to the need to reduce harmful emissions from metallurgy, especially given the high content of arsenic in the ores. This paper describes the investigation of the kinetics of HNO₃ leaching of sulfide gold-containing concentrates of the Yenisei ridge (Yakutia, Russia). The effect of temperature (70–85 °C), the initial concentration of HNO₃ (10–40%) and the content of sulfur in the concentrate (8.22–22.44%) on the iron recovery into the solution was studied. It has been shown that increasing the content of S in the concentrate from 8.22 to 22.44% leads to an average of 45% increase in the iron recovery across the entire range temperatures and concentrations of HNO₃ per one hour of leaching. The leaching kinetics of the studied types of concentrates correlates well with the new shrinking core model, which indicates that the reaction is regulated by interfacial diffusion and diffusion through the product layer. Elemental S is found on the surface of the solid leach residue, as confirmed by XRD and SEM/EDS analysis. The apparent activation energy is 60.276 kJ/mol. The semi-empirical expression describing the reaction rate under the studied conditions can be written as follows: 1/3ln(1 − X) + [(1 − X)^−1/3 − 1] = 87.811(HNO₃)^0.837(S)^2.948e^−60276/RT·t.

This study investigates the use of red muds as adsorbents for As (V) removal. Red mud is a waste that contains a large amount of iron oxides and hydroxides, which are excellent adsorbents of arsenic, especially those possessing magnetic properties and a large specific surface area. The purpose of the experiments was to study the possibility of obtaining an effective adsorbent by the direct extraction of alumina from bauxite using the caustic alkali fusion method and to compare the arsenic removal effectiveness and other properties of these red muds with industrial samples. Red muds were described using methods such as X-ray diffraction spectrometry (XRD), X-ray fluorescence spectrometry (XRF), SEM, vibrating sample magnetometry (VSM), and the Brunauer–Emmett–Teller (BET) method. The main iron-containing phase of the red muds obtained by fusing bauxite with caustic alkali is maghemite, which has a large specific surface area. The specific surface area of the obtained samples varied in the range of 6.1–54.9 m²/g. Arsenic adsorption experiments were carried out using five different types of red muds: industrial Bayer, industrial sintering, and red mud obtained through bauxite alkali fusion at 300, 500, and 700 °C. The red muds obtained by fusing bauxite with caustic alkali at 300 and 500 °C had the highest effectiveness removing arsenic; their As(V) uptake capacity was over 30 mg/g.