Optimization of Red Mud and Blast Furnace Sludge Self-Reducing Briquettes Propaedeutic for Subsequent Magnetic Separation

Red mud, a by-product of aluminum production, leads to significant environmental challenges due to its alkalinity and presence of soluble compounds. This study explores its valorization through agglomeration with blast furnace sludge as a reducing agent to form self-reducing briquettes. Five C/Fe2O3 ratios (0.131, 0.262, 0.523, 0.840 and 1.000) were tested to determine the most effective reducing condition, with 0.840 emerging as optimal based on thermal analysis (mass loss of 27.44 wt.% at 1200 °C and iron formation specific energy of 450 J g−1). Briquettes prepared with three agglomeration methods varying in water content (water/starch ratios of 6:1, 12:1 and 18:1) were evaluated through drop, compression and abrasion tests. The agglomeration method with a 12:1 water/solid ratio, involving both starch gelatinization and red mud water absorption, produced the most mechanically resistant briquettes (19.210 MPa). The mechanical and metallurgical properties of the 0.840-2W briquettes after reduction at 700, 950, 1200 and 1450 °C (temperature maintenance for 15 min) were assessed to define the best compromise between the reduction degree and mechanical strength. While reduction at 950 °C led to the weakest structure (0.449 MPa) but poor metallization, 1450 °C ensured the highest degree of reduction (94%) with adequate brittleness to facilitate a possible subsequent magnetic separation.