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To release the environmental pressure from the massive discharge of bauxite residue (red mud), a novel recycling method of red mud in steel making process was investigated through high-temperature experiments and thermodynamic analysis. The results showed that after the reduction roasting of the carbon-bearing red mud pellets at 1100–1200 °C for 12–20 min, the metallic pellets were obtained with the metallization ratio of ≥88%. Then, the separation of slag and iron achieved from the metallic pellets at 1550 °C, after composition adjustment targeting the primary crystal region of the 12CaO·7Al2O3 phase. After iron removal and composition adjustment, the smelting-separation slag had good smelting performance and desulfurization capability, which meets the demand of sulfurization flux in steel making process. The pig iron quality meets the requirements of the high-quality raw material for steel making. In virtue of the huge scale and output of steel industry, the large-scale consumption and zero-waste recycling method of red mud was proposed, which comprised of the carbon-bearing red mud pellets roasting in the rotary hearth furnace and smelting separation in the electric arc furnace after composition adjustment.

Large-Scale Consumption and Zero-Waste Recycling Method of Red Mud in Steel Making Process