Bauxite residue (BR) is a well promising resource for critical metals, especially scandium (Sc), a rare and expensive metal with increasing applications in advanced technology. Greek BR seems to significantly favor a commercially viable recovery of Sc combining optimized leaching and advanced separation techniques. Leaching with mineral acids emerges as the dominant selection compared to other techniques. This study investigates an optimized leaching condition set for Sc recovery, using the most advantageous option of sulfuric acid. The main target is to develop a leaching scale-up process to be established in the premises of Mytilineos S.A. (formerly Aluminium of Greece, the largest Greek alumina and aluminum producer), taking into account the feed requirements of a subsequent advanced ion exchanged procedure. Several parameters were studied individually or combined in order to achieve high Sc concentration in the leachate and to ensure selectivity, especially concerning iron. The most significant parameters prove to be the solid-to-liquid ratio (S/L), the final pH value, and the leachate’s recycling. The proposed process, with low molarities of sulfuric acid and ambient conditions, integrates rapidly, leading to high and selective Sc recovery. Finally, a leaching process flow diagram under continuous operation on an industrial scale is developed.

Bauxite residue is the voluminous by-product of alumina production after Bayer process. Its high alkalinity causes disposal problems and harmful environmental impacts. However, the residue contains significant amounts of valuable elements, such as rare earth elements, including scandium. Greek bauxite residue contains a high amount of scandium close to its main resources. Taking into account scandium’s limited availability coupled with its high demand in modern technology, bauxite residue could be considered as a potential resource for scandium recovery. In this study, the optimization of scandium extraction from bauxite residue with sulfuric acid is investigated using Taguchi methodology. Based on previous studies, acid molarity, leaching time, solid/liquid ratio, and reaction temperature were selected as control parameters for the selective Sc recovery. Method optimization targeted the highest concentration of scandium combined with the lowest concentration of iron without taking into account application constraints. Maximization of scandium concentration can be achieved only by reduced selectivity. The predicted values resulted from the Taguchi methodology were affirmed by a confirmation experiment conducted at optimal conditions. Regression analysis provided the respective equations to be applied on several conditions, depending on different applications.