Abstract:
The present study developed a novel approach for transforming red mud (RM)
into soft magnetic materials (SMMs) for applications in advanced electrical devices in
the form of Fe-Si and Fe-Si-Al alloys. A total of ten blends were prepared based on
two RMs, three iron oxide additives (Fe2O3, black and red mill scales), alumina and
carbonaceous reductants in a range of proportions. Carbothermic reduction of the blends
was carried out in a vertical Tamman resistance furnace at 1600–1650 ◦C for 30 min in an
argon atmosphere; synthetic graphite was used as a reductant. Reaction products were
characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy
(EDS), X-ray fluorescence (XRF) and X-ray diffraction (XRD). Significant amounts of Fe-rich
metallic droplets/regions of different grain sizes (0.5 to 500 µm) were produced in these
studies. The formation of Fe-Si alloys with Si contents from 3.9 to 6.7 wt.% was achieved in
8 out of 10 blends; the optimal levels of Si for SMMs ranged from 3.2 to 6.5 wt.%. There was
clear evidence for the formation of Fe-Si-Al (up to 1.8 wt.% Al) alloys in 4 out of 10 blends. In
addition to lowering operating challenges associated with RM processing, blending of RMs
with iron oxide additives and alumina presents a novel recycling approach for converting
RMs into valuable SMMs for possible emerging applications in renewable energy, storage,
electrical vehicles and other fields. Along with reducing RM stockpiles across the globe,
this approach is expected to improve resource efficiency, mitigating environmental impacts
while generating economic benefits.
