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Metallurgical grade alumina is produced worldwide through the well-known Bayer process, which unavoidably generates bauxite residue (BR, also known as red mud) in almost equal amounts to alumina. This study aims the valorization of BR through a smelting-reduction process to obtain calcium aluminate slags that can be a proper feed for alumina recovery  via  the Pedersen process. It investigates the thermodynamics and characteristics of the slags and pig iron produced from mixtures of BR, a bauxite beneficiation byproduct, and lime. In this context, the evolution of the different phases in the slags is studied with advanced analytical techniques and thermodynamic calculations. According to the results, a CaO/Al 2 O 3  mass ratio within 1.3 to 1.4 in the slags can yield more Al 2 O 3 -containing leachable phases, such as CaO·Al 2 O 3  and 12CaO·7Al 2 O 3 . The cooling dictates the amount and the characteristics of these phases, and the slower cooling rate yields improved slag characteristics. The distribution of the elements between the slag and metal phases shows that iron is separated, and the majority of the P, Cr, Ni, and V are distributed in the produced pig iron, while S, Ti, and Si are mostly concentrated in the slags.

The Utilization of Bauxite Residue with a Calcite-Rich Bauxite Ore in the Pedersen Process for Iron and Alumina Extraction