Studying the Sintering Behavior of H₂-Reduced Bauxite Residue Pellets Using High-Temperature Thermal Analysis

Treating bauxite residue as an alternative source of metals for iron and aluminum industry is an approach to promote circular economy in metal industries. Reduction of metal oxides with a H₂-based process is an important step for the decarbonization of metal industry. In this study, bauxite residue (BR) pellets were prepared and were reduced with different H₂-H₂O gas compositions at different temperatures, which yielded with various degrees of reduction. The bauxite residue pellets were made from a mixture of bauxite residue and Ca(OH)₂ powders and sintered at 1150 °C. Hydrogen reduction was carried out on the oxide pellets using a resistance furnace at elevated temperatures in controlled reduction atmosphere of H₂-H₂O gas mixtures, which resulted in the reduction of iron oxides in the pellets. Unreduced and reduced pellets were subsequently heated to 1400 °C to study their sintering behavior during H₂ reduction using differential thermal analysis (DTA) and thermogravimetric analysis (TGA) techniques to investigate the evolution of phases related to slag formation. Equilibrium module of Factsage™ was utilized to analyze results of thermal analysis. Both chemical and physical changes that occurred during the sintering process of the H₂-reduced BR pellets were successfully detected by TG-DTA analysis, and the initial slag- and gas-phase formation were detected to occur from 900 °C and 1180 °C, respectively. One of the most notable chemical reactions to occur during the analysis was formation of mayenite at 810 °C, which is easily leachable, providing potential for recovery of alumina.