Joint Thermochemical Activation of Nepheline Ore and Red Mud: Phase Transformations and Alumina Recovery

The efficient processing of nepheline ores and red mud requires mineralogical preconditioning strategies that enhance aluminum recovery while controlling the potassium behavior in alkaline systems. In this study, carbonate–hydrothermal activation of a nepheline ore–red mud mixture (1:1 mass ratio) was investigated as a targeted approach for phase redistribution prior to alkaline leaching. Thermochemical activation in NaHCO3 solution at 260 °C resulted in the partial destabilization of primary aluminosilicate phases and the formation of secondary carbonate-bearing and hydroxide phases. Quantitative phase analysis revealed the formation of cancrinite (~19 wt.%) and boehmite (~2.8 wt.%), indicating dissolution–reprecipitation processes accompanied by aluminum redistribution and carbonate incorporation. A two-stage alkaline leaching process with controlled calcium addition was applied to evaluate the effect of phase transformation on the extraction performance. The activated material exhibited enhanced reactivity, resulting in an alumina recovery of 92%–94% and selective potassium removal of 82%–87%. The results demonstrate that carbonate–hydrothermal activation acts as an effective mineralogical preconditioning strategy, transforming structurally stable aluminosilicates into more reactive phases. The proposed approach provides a basis for improving the efficiency and selectivity of integrated alumina recovery from complex aluminosilicate raw materials and industrial waste.