The objective of this study was to explore the sintering and leaching provision of Bayer’s process waste residue (Red Mud). The chemical composition of red mud was ~16.07% Al2O3, ~53.75% Fe2O3, ~4.24% TiO2, ~8.25% SiO2, ~3.82% Na2O, ~0.148% V2O5, ~0.02% MgO, ~0.157% MnO, ~0.085% Ga2O3, ~0.007% ZnO, 0.099% K2O, ~11.83% LOI (loss on ignition) and rare earth elements in ppm label. The effect of Na2CO3 additive, MgO and Na2CO3 additives, sintering temperature, sintering time and leaching time on the efficiency of alumina extraction from red mud was investigated. Studies show that it was possible to extract alumina from red mud with highest extraction efficiency of 98.70%. The formation of Na2MgSiO4, Mg2SiO4, MgTiO3 and Mg2Fe2O5 phases during sintering of red mud with MgO and Na2CO3, enhance alumina extraction efficiency. X-ray diffractometer and Scanning Electron Microscope studied the formation of Na2MgSiO4, Mg2SiO4, MgTiO3 and Mg2Fe2O5 phases.
Red Mud, Sintering, Leaching, Alumina and Extraction