System and Method for producing Magnetite from Red Mud Using Two Stage Reactors

Technology: Producing Magnetite from Red Mud using Two Stage Reactors;

Industry: Mineral, Environment Engineering, Waste Management, Manufacturing/Chemical

Applications: Waste management;

Market: The global magnetite iron ore market is projected to grow at a CAGR of 5.8% from 2023 to 2031.

In the present era, it is noted that there is growth of Aluminum Industries and associated disposal problems; environmental health is at stake, and therefore, remedial actions are required. Further, red mud also possesses some valuable elements such as iron which can be extracted in the form of Magnetite instead of large-scale dumping in the environment.
By literature survey, it is found that the conventional process is not efficient in terms of the conversion process. Hence, there is a need for a system to mitigate the above challenges efficiently.

The present invention describes a system for continuous extraction of magnetite from red mud.
Said system comprises a plurality of two stage reactors attached in a serial connection; and operates in charging mode, pre-heating mode, first & second reaction modes, & discharging mode sequentially with a predetermined time lag of 5-15 minutes.
The system includes a wet magnetic separator configured to separate magnetite from non-magnetic particles in the slurry.
The reactors are configured to operate in charging, preheating, reaction and discharging modes with a time lag Δt, and wherein the each two-stage reactor operating in the reaction modes mode produces hot gas, that is supplied to another two-stage reactor operating in pre-heating mode, & each two-stage reactor operating in the discharging mode receives cold gas that is heated and supplied as hot input gas to another two-stage reactor operating in pre-heating mode.
Further, said patent describes a method for producing magnetite from red mud using a plurality of two stage reactors.
The system for producing magnetite from red mud is depicted in the figures. (Refer Figures)

Technical Perspective:

The reactors are connected serially to transfer pre-heated air, improving energy efficiency during magnetite production.
The magnetite slurry is processed using magnetic separation to obtain a 95% or better magnetite concentration.

Industrial Perspective:

Prof. Sabita Sarkar

Department of Metallurgical and Materials Engineering

TRL-4

Proof of Concept ready, tested in lab.

Technology Transfer