Geomega Resources Inc., in collaboration with Rio Tinto, has shared a significant update on its bauxite residue valorization pilot project, first launched in March 2022. The project focuses on advancing Geomega’s proprietary technology to transform bauxite residue—commonly known as red mud—into valuable products, while minimizing waste and environmental impact.

The valorization technology developed by Geomega is structured into three sequential circuits, each addressing a specific component of the residue. Depending on a refinery's residue composition and corporate objectives, they may license Circuit 1 alone, Circuits 1 and 2 together, or the full package including Circuit 3.

Circuit 1 (C1) is designed to reduce alkalinity and extract valuable products such as sodium, calcium, aluminum, and silica. It contributes to a 10% to 30% reduction in waste volume.

Circuit 2 (C2) targets iron extraction, producing high-purity iron feedstock like Direct Reduced Iron (DRI) grade ore, essential for low-carbon steelmaking. Combined, C1 and C2 account for over 70% of total waste reduction.

Circuit 3 (C3) focuses on the recovery of critical and high-value metals. Currently in development, this circuit aims to efficiently extract and purify rare earth elements (REE), titanium, and potentially scandium, gallium, alumina, and silica. A notable innovation is the integrated reagent recycling system in each circuit, ensuring minimal effluent and eliminating the production of hazardous waste. Impressively, over 95% of the main reagents in C1 and C2 are recycled, significantly lowering operational costs.

Over the past three years, Geomega has conducted multiple rounds of bench and pilot scale testing to validate and refine the technology. These tests produced samples for performance validation and product optimization. Rio Tinto provided specific purity and particle size criteria, all of which have been successfully achieved and confirmed by their team.

Pilot testing for Circuits 1 and 2 is now complete, allowing for the creation of representative residue samples to begin testing for Circuit 3, which is scheduled for 2025. Based on the successful outcomes thus far, Geomega and Rio Tinto have extended their collaboration agreement to proceed with the development of C3. Concurrently, both companies are preparing for the next development phase of C1 and C2.

Kiril Mugerman, President and CEO of Geomega, praised the progress, stating that the technology presents an economical and sustainable solution for the aluminum industry while unlocking a vital supply of critical metals. Josette Ross, General Manager at Rio Tinto’s Arvida Research and Development Center, echoed this sentiment, emphasizing the importance of research partnerships in supporting sustainable aluminum production.