Innovative and Sustainable Valorization Process to Recover Scandium and Rare Earth Elements from Canadian Bauxite Residues

Bauxite residue is an environmentally unfriendly byproduct of alumina manufacturing, produced worldwide in large quantities. This material contains 50–100 ppm of scandium, a critical material for the production of stronger, weldable, corrosion resistant, and heat tolerant aluminum products. Aircraft manufacturers are particularly interested in Al–Sc alloys because of its ability to form weldable alloys that could potentially reduce aircraft weight by 15–20%. Because of its abundance and low cost, bauxite residue has the potential to be used as an efficient feedstock for valorization processes to recover its scandium content, while in turn degrading this problematic waste. In this project, we developed an efficient process to recover scandium and rare earth elements from a Canadian bauxite residue with high extraction yields, using industrially scalable and economical techniques. The process employs a modified version of sulfuric acid leaching and subsequent impurity removal by selective precipitation. This article outlines the current progress and design rationale in the development and optimization of this innovative and sustainable recovery process.