Advancing Iron Recovery from Red Mud: Green Pathways, Synergistic Valorization, and High-Value Total Component Utilization

Facing the severe environmental challenge of massive red mud (RM) stockpiles, iron extraction research is accelerating from traditional pyrometallurgy and other conventional processes toward green low-carbon, multi-source synergistic, and total-component high-value utilization approaches—a transition that continues to evolve. This review systematically examines three frontiers: green reduction technologies, synergistic valorization via waste-treating-waste, and integrated cascading strategies for total-component high-value utilization. Evaluation focuses on the principles, advantages, and challenges of biomass reduction, hydrogen metallurgy, selective flocculation, advanced heating techniques, co-processing with other solid wastes, and multi-metal cascading extraction. Evidence suggests that future RM iron extraction technology lies in establishing cross-industry circular economy networks, transforming RM from a singular waste into a resource hub linking aluminum, steel, and construction industries to maximize environmental and economic benefits.