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Preliminary Economic Analysis of Red Mud Valorization via Colloidal Aqueous Electrolytic Reduction in a Modern Electricity Infrastructure

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Abstract

Electrolytic reduction (ER) of hematite (Fe2O3) can serve as a low-direct-emissions production method for powder ferrometallurgy against traditional blast furnace (BF) and direct reduction (DR) methods. Use of ER in these contexts will also allow for valorization of hematite-rich waste feeds such as red mud. This study performs a techno-economic analysis on a low-temperature aqueous ER technology to determine the value of the process and its products at a scale of 100,000 tons red mud processed per year. The study is performed under several electricity pricing scenarios, for which the material, energy, economic, and emissions impacts are developed and compared to incumbent technologies. Monte Carlo simulations were performed to account for uncertainties surrounding variable feedstock composition and process parameters. It was found that hematite content and conversion rate were the most sensitive variables, followed by electricity pricing. The iron powder product has an expected minimum selling price of ~ $1450/ton when operating on feeds with ~ 50 wt% Fe2O3, under processes with ~ 66 mol% conversion and ~ 70% Faradaic efficiency. The studied electricity sources had minimal impact on iron selling price, but renewable electricity sourcing significantly undercuts carbothermic process emissions. Because of the high cost and small scale relative to bulk iron manufacture, this process could find a niche in valorizing red mud to produce a high-quality iron powder for additive manufacturing or powder metallurgy industries in addition to reducing red mud causticity and promoting downstream purification of the outlet stream.

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Acknowledgements

The authors are grateful to Prof. Nikolaos Kazantzis for assistance with Monte Carlo cost modeling methodology.

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Authors and Affiliations

  1. Department of Chemical Engineering, Worcester Polytechnic Institute, Worcester, MA, USA

    Muntasir Shahabuddin

  2. Department of Mechanical and Materials Engineering, Worcester Polytechnic Institute, Worcester, MA, USA

    Adam C. Powell IV & Yan Wang

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  1. Muntasir Shahabuddin
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Correspondence to Adam C. Powell IV.

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Shahabuddin, M., Powell, A.C. & Wang, Y. Preliminary Economic Analysis of Red Mud Valorization via Colloidal Aqueous Electrolytic Reduction in a Modern Electricity Infrastructure. J. Sustain. Metall. 8, 900–912 (2022). https://doi.org/10.1007/s40831-022-00537-5

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