Bauxite residue is the voluminous by-product of alumina production after Bayer process. Its high alkalinity causes disposal problems and harmful environmental impacts. However, the residue contains significant amounts of valuable elements such as rare earth elements including scandium. Greek bauxite residue contains a high amount of scandium close to its main resources. Taking into account scandium limited availability coupled with its high demand in modern technology, bauxite residue could be considered as a potential resource for scandium recovery. In this study, the optimization of scandium extraction from bauxite residue with sulfuric acid is investigated using Taguchi methodology. Based on previous studies acid molarity, leaching time, solid/liquid ratio and reaction temperature were selected as control parameters for the selective Sc recovery. Method optimization targeted the highest concentration of scandium combined with the lowest concentration of iron without taking into account applications constraints. The predicted values resulted by Taguchi methodology were affirmed by a confirmation experiment conducted at optimal conditions. Regression analysis provided the respective equations to be applied on several conditions depending on different applications.

Aiming at the industrial scale development of a Scandium (Sc)-selective leaching process of Bauxite Residue (BR), a sufficiently numerous set of process design aspects has been investigated, by appropriate exploitation of available experimental data. The interpretation of experimental data for Sc leaching yield, with sulfuric acid as the leaching solvent, has shown significant impact from acid feed concentration, mixing residence time, liquid to solids ratio, and times of leachate re-usage onto fresh BR. The thin film diffusion model, as the fundamental theory for leaching, either with constant particle size for selective leaching, or with shrinking particle size for less-, or non-, selective leaching, interprets sufficiently well the relevant experimental data. In both cases, a concept for an unyielding core supplements the basic model. Especially for the selective leaching mild conditions, the simplest model version keeps step with the experiments, since both prove 1^st order kinetics, while especially for the extreme conditions including very low solvent excess, it is proposed a combined conversion rate model with diffusion and chemical reaction inside particles. The maximization of Sc recovery per unit of consumed solvent (i.e., specific recovery) emerged as highly critical for the process economics.

Bauxite residue (BR) is a well promising resource for critical metals and especially scandium (Sc), a rare and expensive metal with increasing applications in advanced technology. Particularly, Greek BR’s composition indicates a sound possibility for a commercially viable recovery of Sc under the conditions of an optimized leaching process and the subsequent use of advanced separation techniques. Leaching with mineral acids emerges as the dominant selection with comparison to other techniques. This study investigates an optimized leaching condition set on Sc recovery, using sulfuric acid as the most suitable among different acids tested, in the context of process economics and environmental constraints. Several variables were studied individually or combined in order to achieve high Sc concentration in the leachate as well as to ensure selectivity, especially in respect to iron. The most significant parameters proved to be the solid to liquid ratio (S/L), the final pH value as well as the use of recycling of leachate on fresh BR batches. The proposed process, using sulfuric acid at low acid molarities under ambient conditions was integrated rapidly leading to high and selective Sc recovery. A flow diagram of the developed leaching process in industrial scale was proposed based on continuous operation.