New flash process cuts 96% of metals, keeps aluminum in red mud

Researchers at Rice University have developed a rapid and environmentally friendly method to treat bauxite residue, known as red mud, a toxic by-product of aluminum production. Their technique uses flash Joule heating (FJH), which applies a high-power electrical pulse for under one minute, combined with a small amount of chlorine gas to vaporize hazardous metals. This process removes 96% of iron and nearly all toxic metals while preserving almost all the aluminum content. Unlike traditional methods, it avoids the use of water, solvents, and corrosive chemicals, resulting in a safer, aluminum-rich residue that can be recycled back into aluminum production or converted into durable ceramic building materials. This breakthrough offers significant industrial and environmental benefits by reducing waste piles, lowering emissions, and decreasing the need for new bauxite mining. The cleaned red mud can be transformed into super-hard ceramics suitable for construction, turning a hazardous waste into a valuable resource. The Rice team is collaborating with industry partners through Flash Metals USA, a spinoff company