In Limerick, Ireland, an innovative project at the Aughinish aluminum refinery is turning industrial waste into opportunity by paving a 500-meter road with bauxite residue, commonly known as red mud. This initiative is part of the EU-funded RemovAL project which aims to address the environmental challenges posed by aluminum production waste.
Dr. Efthymios Balomenos, co-leader of the RemovAL project, emphasized the goal to shift away from landfill practices, noting the substantial waste aluminum production generates—about two tonnes of bauxite residue for every tonne produced. Annually, the aluminum industry produces approximately 150 million tonnes of red mud globally, with less than 3% currently recycled.
The RemovAL project, involving partners like Rio Tinto and Mytilineos, tested commercial uses for bauxite residue at sites across Germany, Greece, and Ireland. The project demonstrated that bauxite residue could serve as a subbase layer for roads, providing a stable foundation traditionally made from low-grade crushed stone. Moreover, the project extracted valuable materials like iron and rare earth elements scandium from the residue, enhancing the EU’s efforts to reduce reliance on foreign industrial commodities.
Despite technical successes, financial viability remains a hurdle, as recycled materials often cost more than virgin raw materials. Dr. Balomenos suggests that for the green transformation of the aluminum sector, Europe might need regulatory incentives or subsidies.
Additionally, the EU-supported NEMO project addressed waste from copper, zinc, lead, and nickel mining. Researchers tested bioleaching techniques to recover metals from mine tailings, potentially transforming these into safer additives for cement manufacturing. However, like RemovAL, NEMO faced challenges in making these processes economically feasible.
