Technology Development of Rare Earth Metals Recovery in the Closed Cycle of Red Mud Processing

Collaborative Research Program for 2025-2027

The project (DREAMS) aims to enhance competitiveness and generate added value in the processing of critical raw materials, equipment manufacturing, and downstream industries. The proposed methods for the recovery of rare earth metals (REMs) will be investigated for the first time in the context of primary extraction from Kazakh and Turkish red mud (RM) materials. The prime target of the proposed project “DREAMS-Technology Development of Rare Earth Metals Recovery in the Closed Cycle of Red Mud Processing” is to pioneer an innovative approach for the improved utilization of mineralogically distinct RM samples, sourced from both Kazakhstan and Turkey origin. Specific metal oxides such as TiO2, V2O5, metallic gallium & REMs including Ce, La, Nd, Y, and Sc will be selectively concentrated and recovered from the distinct RM samples and an integrated waste-to-resource technique will be adopted for the selective extraction of rare earth elements (REEs) via pretreatment methods plus microwave synthesis, and chemical processing routes, followed by a comparative analysis and process scale-up to a semi-pilot scale. This approach represents the key aspect of the current investigation. The proposed technology within the project lies in the closed-loop processing of RM. This includes microwave synthesis to create the active form of calcium additive for autoclave leaching of RM, and processing of hard-to-recover iron slag using microwave and chemical activation. This should increase the country's economic potential by organizing the production and sale of acutely deficient rare metals and REEs. Recycling gallium from alumina waste is a critical means of expanding raw materials sources, ensuring a more reliable supply of this rare metal. Titanium and titanium alloys are ideal candidates for aerospace and other high-tech applications. By-product recovery of titanium from industrial waste will expand the scarce mineral resource base and make it an affordable material. The rare metal vanadium (V) and its compounds are used in a variety of industrial sectors to optimize the performance characteristics of the resulting products. Since vanadium does not have its own mineral deposits and its production is based on by-product recovery during the complex processing of ore raw materials. Using innovative technical solutions, the project addresses the issues of efficient associated extraction of REEs and rare metals in the processing of red mud, a multi-tonnage technogenic waste material.

The project concept is intended to elevate the present technologies from Technology Readiness Level (TRL) 3 to 5 and TRL 7 for pilot validation, reflecting significant progress in technology development and technology demonstration. The proposal is in the scope of the topic priorities (NU Research Priorities, Kazakhstan Research Priorities, and UN Sustainable Development Goals) and focuses adapting both and existing techniques. DREAMS technology will have a significant impact on global and important markets for aluminum production, with the by-product of rare metals and REEs through the introduction of new sustainable technologies. The project aims to seamlessly transition the achieved outcomes into industrial applications, leveraging the interest of industrial companies for the subsequent exploitation of the results. This project presents an opportunity to enhance technology transfer and R&D activities, including patenting, thereby fostering economic development in the region. Subsequent research endeavors, potentially through future project proposals, targeting the development of industrial-scale products and prototypes, as well as the exploration of licensing and/or establishment of Spin-off/Start-up companies, will strengthen the economic foundation. This will be achieved by bringing to market a commercially viable technology that is readily available for application in various industries.