Hydrogen As the Reducing Agent in the REcovery of metals and minerals from metallurgical waste

Project Information

HARARE

Grant agreement ID: 958307

DOI

10.3030/958307

Project closed

EC signature date 7 May 2021

Start date 1 June 2021

End date 30 November 2025

Funded under

• SOCIETAL CHALLENGES - Climate action, Environment, Resource Efficiency and Raw Materials

Total cost

€ 9 455 632,51

EU contribution

€ 8 589 910,13

Coordinated by

SINTEF AS
Norway

CORDIS provides links to public deliverables and publications of HORIZON projects.

Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .

Deliverables

Documents, reports (7)

"Report on international seminar on ""Hydrogen use in process metallurgy"""

Report on international seminar on ”Hydrogen use in process metallurgy”

Resource mapping report other waste and by-product streams

Resource mapping report other waste and by-product streams.

Communication Plan
Resource mapping report on bauxite residue

Resource mapping report on bauxite residue.

Dissemination plan.
Recommendation and design for safe use of hydrogen in lab and pilot scale experiments

Recommendation and design for safe use of hydrogen in lab and pilot scale experiments including design of suitable regulation and control of hydrogen supply systems.

Resource mapping report on copper slag

Resource mapping report on copper slag.

Open Research Data Pilot (1)

Open data management plan

Open data management plan.

Publications

Peer reviewed articles (29)

Pilot Scale Hydrogen (H2) Reduction of Bauxite Residue for the Production of Magnetite and Water-Soluble Sodium Aluminate

Author(s): Ganesh Pilla, Glenn Beersaerts, Tobias Hertel, Yiannis Pontikes
Published in: Journal of Sustainable Metallurgy, Issue 11, 2025, Page(s) 1554-1570, ISSN 2199-3823
Publisher: Springer Science and Business Media LLC
DOI: 10.1007/s40831-025-01068-5

Multi-Objective Optimization of Blended Cement Mortars from Copper Slags

Author(s): Debadri Som, Tobias Hertel, Glenn Beersaerts, Panagiotis Patrinos, Yiannis Pontikes
Published in: SSRN, 2025, ISSN 1556-5068
Publisher: Elsevier
DOI: 10.2139/ssrn.5130886

An Overview Analysis of Current Research Status in Iron Oxides Reduction by Hydrogen

Author(s): Zuzana Miškovičová, Jaroslav Legemza, Peter Demeter, Branislav Buľko, Slavomír Hubatka, Martina Hrubovčáková, Peter Futáš, Róbert Findorák
Published in: Metals, Issue 14, 2025, Page(s) 589, ISSN 2075-4701
Publisher: MDPI AG
DOI: 10.3390/met14050589

Characteristics of Bauxite Residue–Limestone Pellets as Feedstock for Fe and Al2O3 Recovery

Author(s): Manish Kumar Kar; Jafar Safarian
Published in: Processes, Issue Volume 11; Issue 1, 2023, Page(s) 137, ISSN 2227-9717
Publisher: MDPI
DOI: 10.3390/pr11010137

High-temperature heat treatment of hydrogen-reduced bauxite residue-calcite pellets for iron particles growth and separation

Author(s): Manish Kumar Kar, Jafar Safarian
Published in: Canadian Metallurgical Quarterly, Issue 64, 2025, Page(s) 731-744, ISSN 0008-4433
Publisher: Maney Publishing
DOI: 10.1080/00084433.2024.2378268

Comparative Study of Hydrogen Reduction of Bauxite Residue-Calcium Sintered and Self-Hardened Pellets Followed by Magnetic Separation for Iron Recovery

Author(s): Manish Kumar Kar; Ahmad Hassanzadeh; Casper van der Eijk; Jafar Safarian
Published in: Mining, Metallurgy & Exploration, Issue 40, 2023, Page(s) 2037-2050, ISSN 0967-0912
Publisher: Institute of Materials
DOI: 10.1007/s42461-023-00882-3

Towards sustainable valorization of bauxite residue: Thermodynamic analysis, comprehensive characterization, and response surface methodology of H2 reduced products for simultaneous metal recovery

Author(s): Ganesh Pilla, Tobias Hertel, Alexios P. Douvalis, Stergi Kapelari, Bart Blanpain, Yiannis Pontikes,
Published in: Journal of Cleaner Production, Issue 440, 2024, Page(s) 140931, ISSN 0959-6526
Publisher: Elsevier BV
DOI: 10.1016/j.jclepro.2024.140931

Comparative kinetics study of different iron-containing pellets with hydrogen at isothermal conditions

Author(s): Kar, Manish Kumar; Mengyi, Zhu; Safarian, Jafar
Published in: Journal of Materials Research and Technology, Issue 27, 2023, Page(s) 8062-8072, ISSN 2214-0697
Publisher: Elsevier
DOI: 10.1016/j.jmrt.2023.11.248

Iron enrichment and alumina recovery from bauxite residue through hydrogen reduction followed by alkaline leaching and CaO circulation

Author(s): Manish Kumar Kar, Mengyi Zhu, Jafar Safarian
Published in: Canadian Metallurgical Quarterly, Issue 64, 2025, Page(s) 2486-2499, ISSN 0008-4433
Publisher: Maney Publishing
DOI: 10.1080/00084433.2024.2437225

Toward an Integrated and Sustainable Bauxite Residue Valorization, Employing H2 Reduction Roasting, Carbonation, and Bio-carbon Smelting

Author(s): Ganesh Pilla, Tobias Hertel, Yiannis Pontikes
Published in: Journal of Sustainable Metallurgy, Issue 11, 2025, Page(s) 1745-1765, ISSN 2199-3823
Publisher: Springer Science and Business Media LLC
DOI: 10.1007/s40831-025-01077-4

Isothermal Hydrogen Reduction of a Lime-Added Bauxite Residue Agglomerate at Elevated Temperatures for Iron and Alumina Recovery

Author(s): Olivia Bogen Skibelid; Sander Ose Velle; Frida Vollan; Casper Van der Eijk; Arman Hoseinpur-Kermani; Jafar Safarian
Published in: Materials, Issue 17, 2022, Page(s) 6012, ISSN 1996-1944
Publisher: MDPI Open Access Publishing
DOI: 10.3390/ma15176012

An Investigation on Reduction of Calcium Added Bauxite Residue Pellets by Hydrogen and Iron Recovery through Physical Separation Methods

Author(s): Ahmad Hassanzadeh; Manish K. Kar; Jafar Safarian; Przemyslaw B. Kowalczuk
Published in: Metals, Issue 13(5), 2023, Page(s) 946, ISSN 2075-4701
Publisher: MDPI
DOI: 10.3390/met13050946

A study on non-isothermal hydrogen reduction of different bauxite residue–calcium pellets for feasible recoverability of iron and alumina

Author(s): Manish Kumar Kar, Ahmad Hassanzadeh, Casper van der Eijk, Pshem Kowalczuk, Kurt Aasly, Jafar Safarian
Published in: Mineral Processing and Extractive Metallurgy: Transactions of the Institutions of Mining and Metallurgy, Issue 134, 2025, Page(s) 79-95, ISSN 2572-6641
Publisher: SAGE Publications
DOI: 10.1177/25726641251324041

Selective Scandium Elution from D2EHPA-Impregnated Ion-Exchange Resin After Metal Loading from Acidic Chloride Solutions

Author(s): Eleni Mikeli, Danai Marinos, Efthymios Balomenos, Dimitrios Panias
Published in: Materials, Issue 17, 2025, Page(s) 6089, ISSN 1996-1944
Publisher: MDPI Open Access Publishing
DOI: 10.3390/ma17246089

Introducing key advantages of intensified flotation cells over conventionally used mechanical and column cells

Author(s): Ahmad Hassanzadeh; Mehdi Safari; Hamid Khoshdast; Mustafa Güner; Duong Hoang; Tim Sambrook; Przemyslaw Kowalczuk
Published in: Physicochem. Probl. Miner. Process., Issue 58(5), 2022, Page(s) 155101, ISSN 1643-1049
Publisher: Wroclaw University of Science and Technology
DOI: 10.37190/ppmp/155101

Hydrogen Reduction of Bauxite Residue for Green Steel and Sustainable Alumina Production

Author(s): Manish Kumar Kar, Mengyi Zhu, Jafar Safarian
Published in: Journal of Sustainable Metallurgy, Issue 11, 2025, Page(s) 1363-1380, ISSN 2199-3823
Publisher: Springer Science and Business Media LLC
DOI: 10.1007/s40831-025-01046-x

Properties of self-hardened CaO-added bauxite residue pellets, and their behavior in hydrogen reduction followed by leaching and magnetic separation for iron and alumina recovery

Author(s): Manish K. Kara, Ahmad Hassanzadeh, Casper van der Eijk, Przemyslaw B. Kowalczuk, Kurt Aasly, Jafar Safarian
Published in: International Journal of Hydrogen Energy, Issue 48(99), 2023, Page(s) 38976-38990, ISSN 0360-3199
Publisher: Pergamon Press Ltd.
DOI: 10.1016/j.ijhydene.2023.09.212

Hydrogen reduction of bauxite residue and selective metal recovery

Author(s): Pilla, Ganesh; Kapelari, Stergi; Hertel, Tobias; Blanpain, Bart; Pontikes, Yiannis
Published in: Materials Today: Proceedings, Issue 57, 2022, Page(s) 705-710, ISSN 2214-7853
Publisher: Elsevier
DOI: 10.1016/j.matpr.2022.02.152

Sustainable recovery of metallic Fe and oxides from bauxite residue via H2 reduction: Enhancing purity and recovery rates

Author(s): Ganesh Pilla, Tobias Hertel, Bart Blanpain, Yiannis Pontikes
Published in: Sustainable Materials and Technologies, Issue 43, 2026, Page(s) e01289, ISSN 2214-9937
Publisher: Elsevier BV
DOI: 10.1016/j.susmat.2025.e01289

Kinetics Study on the Hydrogen Reduction of Bauxite Residue-Calcite Sintered Pellets at Elevated Temperature

Author(s): Kar, Manish Kumar; van der Eijk, Casper; Safarian, Jafar
Published in: Metals, Issue 13(4), 2023, Page(s) 644, ISSN 2075-4701
Publisher: MDPI
DOI: 10.3390/met13040644

The Effect of Composition and Temperature on the Hydrogen Reduction Behavior of Sintered Pellets of Bauxite Residue-Lime Mixtures

Author(s): Kar, M. K., Eijk, C. van . der . and Safarian, J.
Published in: Journal of Sustainable Metallurgy, 2024, ISSN 2199-3831
Publisher: Springer
DOI: 10.1007/s40831-024-00849-8

Producing High Purity Metallic Iron from Bauxite Residue through Hydrogen Reduction Followed by Flux Smelting

Author(s): Manish Kumar Kar, Jafar Safarian
Published in: ISIJ International, Issue 65, 2025, Page(s) 372-383, ISSN 0915-1559
Publisher: Nippon Tekko Kyokai/Iron and Steel Institute of Japan
DOI: 10.2355/isijinternational.isijint-2024-341

Studying the Sintering Behavior of H2-Reduced Bauxite Residue Pellets Using High-Temperature Thermal Analysis

Author(s): Dali Hariswijaya, Jafar Safarian
Published in: Materials, Issue 18, 2025, Page(s) 2378, ISSN 1996-1944
Publisher: MDPI Open Access Publishing
DOI: 10.3390/ma18102378

Numerical study on the gas-liquid interface in the hydrogen reduction of copper slag process

Author(s): Zhongfu Cheng; Bart Blanpain
Published in: Chemical Engineering Science, Issue 290, 2024, Page(s) 119916, ISSN 1873-4405
Publisher: Elsevier
DOI: 10.1016/j.ces.2024.119916

A sustainable approach for concurrent recovery of metals from H2 reduced bauxite residue (“red mud”): Process optimization

Author(s): Ganesh Pilla, Tobias Hertel, Bart Blanpain, Yiannis Pontikes
Published in: Resources, Conservation and Recycling, Issue 215, 2025, Page(s) 108051, ISSN 0921-3449
Publisher: Elsevier BV
DOI: 10.1016/j.resconrec.2024.108051

Complementary approaches in characterization of secondary raw materials: a case study of H2-reduced bauxite residue

Author(s): Hassanzadeh, Ahmad; Lode, Stefanie; Pilla, Ganesh; Røstad, Jostein; Kowalczuk, Przemyslaw
Published in: Process Mineralogy 2022, Issue 1, 2022, ISSN 1617-4011
Publisher: Mei conferences
DOI: 10.5281/zenodo.7595289

An Invitation on Characterization of H2-Reduced Bauxite Residue and Recovering Iron through Wet Magnetic Separation Processes

Author(s): Ahmad Hassanzadeh; Ganesh Pilla; Manish K. Kar; Przemyslaw B. Kowalczuk
Published in: Minerals, Vol 13, Iss 6, p 728 (2023), Issue 3, 2023, Page(s) 728, ISSN 2075-163X
Publisher: MDPI
DOI: 10.3390/min13060728

Hydrogen Reduction of Bauxite Residue-Calcite Pellets and Mechanisms of Iron Particles Growth: A Comparative Study at Lab and Pilot Scales

Author(s): Manish Kumar Kar, Frida Vollan, Casper van der Eijk, Jafar Safarian
Published in: Metallurgical and Materials Transactions B, 2025, ISSN 1073-5615
Publisher: ASM International
DOI: 10.1007/s11663-025-03898-w

Hydrogen reduction of bauxite residue pellets and effect of calcite addition

Author(s): Manish Kumar Kar, Adamantia Lazou, Efthymios Balomenos, Casper Van Der Eijk, Jafar Safarian
Published in: ISIJ International, 2026, ISSN 0915-1559
Publisher: Nippon Tekko Kyokai/Iron and Steel Institute of Japan
DOI: 10.2355/isijinternational.isijint-2025-234

Conference proceedings (18)

Studying the smelting behaviour of bauxite residue pellets reduced by hydrogen using high temperature thermal analysis

Author(s): null null, D Hariswijaya, J Safarian, null null
Published in: 12th International Conference of Molten Slags, Fluxes and Salts (MOLTEN 2024) Proceedings, 2024, Page(s) 361-374
Publisher: Australasian Institute of Mining and Metallurgy (AusIMM)
DOI: 10.62053/gacj7735

Water and Alkali Leaching for Simultaneous Iron and Alumina Separation from Hydrogen-Reduced Bauxite Residue-Calcite Pellets

Author(s): Kar, Manish Kumar, Casper van der Eijk, and Jafar Safarian
Published in: Materials Proceedings, Issue 15, No. 1, 2023, Page(s) 42, ISSN 2673-4605
Publisher: MDPI
DOI: 10.3390/materproc2023015042

Possibilities and Limitations of the Use of Hydrogen in Different Metallurgical Sectors

Author(s): Casper Eijk, Halvor Dalaker, Jafar Safarian
Published in: RawMat 2023, 2025, Page(s) 63
Publisher: MDPI
DOI: 10.3390/materproc2023015063

Possibilities and Limitations of the Use of Hydrogen in Different Metallurgical Sectors

Author(s): Eijk, Casper van der, Halvor Dalaker, and Jafar Safarian
Published in: Materials Proceedings, Issue 15, No. 1, 2023, Page(s) 63, ISSN 2673-4605
Publisher: MDPI
DOI: 10.3390/materproc2023015063

Reactions and Phase Transformations During the Low-Temperature Reduction of Bauxite Residue by H2 in the Presence of NaOH, and Recovery Rates Downstream

Author(s): Pilla, Ganesh; Hertel, Tobias; Kapelari, Stergi; Blanpain, Bart; Pontikes, Yiannis
Published in: TRAVAUX 51, Proceedings of the 40th International ICSOBA Conference, 2022, Page(s) 801, ISSN 2518-332X
Publisher: Icsoba
DOI: 10.5281/zenodo.7497901

Hydrogen Reduction of High Temperature Sintered and Self-Hardened Pellets of Bauxite Residue produced via the Addition of Limestone and Quicklime

Author(s): Kar, Manish Kumar; Eijk, Casper van der; Safarian, Jafar
Published in: TRAVAUX 51, Proceedings of the 40th International ICSOBA Conference, 2022, Page(s) 823, ISSN 2518-332X
Publisher: Icsoba
DOI: 10.5281/zenodo.7497907

Effect of H2-H2O mixture composition on reducibility of bauxite residue pellets

Author(s): Hariswijaya, Dali
Published in: International seminar on Hydrogen use in Process Metallurgy, 2024
Publisher: NTNU
DOI: 10.5281/zenodo.12513923

"Optimization of Fe, Al, and Na recovery from H2 Reduced Bauxite Residue (""red mud"") using Response Surface Methodology (RSM)"

Author(s): Pilla, Ganesh, Tobias Hertel, and Yiannis Pontikes
Published in: Materials Proceedings, Issue 15, No. 1, 2023, Page(s) 85, ISSN 2673-4605
Publisher: MDPIU
DOI: 10.3390/materproc2023015085

Experimental Study on Hydrogen Reduction of Bauxite Residue Pellets Using H2-H2O Mixtures.

Author(s): Hariswijaya, D., Trondsen Dahl, E., Ragnhildstveit Erland, S., & Safarian, J
Published in: Proceedings of the 41st International ICSOBA Conference (ICSOBA), 2024
Publisher: Icsoba
DOI: 10.5281/zenodo.13740944

"Sustainable valorization of Bauxite residue (""red mud""): Exploring the potential of H2 reduction for multi-metal recovery."

Author(s): Ganesh Pilla, Tobias Hertel and Yiannis Pontikes
Published in: Light metals 2024, 2024, Page(s) 110-117, ISBN 978-3-031-50308-5
Publisher: TMS 2024. The Minerals, Metals & Materials Series. Springer
DOI: 10.1007/978-3-031-50308-5_13

High-Temperature Hydrogen Reduction of Bauxite Residue for Iron Recovery

Author(s): Hoseinpur, Arman; Friborg, Per Ivar; Van der Eijk, Casper; Safarian, Jafar
Published in: Proceedings of the 61st Conference of Metallurgists, COM 2022, 2023, Page(s) 119–127, ISBN 978-3-031-17425-4
Publisher: Springer
DOI: 10.1007/978-3-031-17425-4_19

Screening strategy for Fe-rich slag-based mortars

Author(s): Debadri Som, Tobias Hertel, Glenn Beersærts, Rahul Roy, Ganesh Pilla, Yiannis Pontikes
Published in: Slag valorisation symposium 2023, 2023
Publisher: KU Leuven
DOI: 10.5281/zenodo.12205198

Hydrogen reduction of Bauxite residue pellets and effect of calcite addition

Author(s): Manish Kumar Kar, Casper van der Eijk, Efthymios Balomenos and Jafar Safarian
Published in: Proceedings of EMC 2023, 2023, Page(s) 35, ISBN 978-3-935797-35-1
Publisher: GDMB
DOI: 10.5281/zenodo.12090959

Fuming process of zinc rich slags by hydrogen injection

Author(s): Gunnar Hovestadt, Bernd Friedrich
Published in: Slag valorisation symposium 2023, 2023
Publisher: KU Leuven
DOI: 10.5281/zenodo.12652872

Computational fluid dynamics simulation of hydrogen conversion in the reduction of copper slag

Author(s): Zhongfu Cheng, Gunnar Hovestadt, Bernd Friedrich, Bart Blanpain
Published in: Slag valorisation symposium 2023, 2023
Publisher: KU Leuven
DOI: 10.5281/zenodo.12653519

Influence of H2 content on Fe, Al, and Na recovery during low-temperature reduction of bauxite residue

Author(s): Ganesh Pilla, Hertel, T., Blanpain, B., Pontikes, Y.
Published in: Slag valorisation symposium 2023, 2023
Publisher: KU Leuven
DOI: 10.5281/zenodo.12089723

Determining critical parameters of hydrogen reduction treatment of low copper-containing primary slags

Author(s): Gunnar Hovestadt, Marvin Coldewe, Bernd Friedrich
Published in: Proceedings of EMC 2023, 2023, Page(s) 75, ISBN 978-3-935797-35-1
Publisher: GDMB
DOI: 10.5281/zenodo.12205242

Recovery of Copper, Iron, and Alumina from Metallurgical Waste by Use of Hydrogen

Author(s): Van der Eijk, Casper; Dalaker, Halvor
Published in: REWAS 2022: Developing Tomorrow’s Technical Cycles (Volume I). The Minerals, Metals & Materials Series., 2022, Page(s) 729–737, ISBN 978-3-030-92563-5
Publisher: Springer Nature
DOI: 10.1007/978-3-030-92563-5_75

Other (4)

"HYDROGEN (H2) REDUCTION OF BAUXITE RESIDUE (""RED MUD""): FROM LABORATORY TO PILOT-SCALE."

Author(s): Pilla, G., Beersaerts, G., Hertel, T., & Pontikes, Y.
Published in: 9th International Slag Valorisation Symposium, 2025
Publisher: KU Leuven
DOI: 10.5281/zenodo.18390170

Acid Leaching of Cu/Fe polymetallic alloy: Process alternatives & Challenges

Author(s): Vafeias, Michail
Published in: 2nd International Conference on Raw Materials and Circular Economy (RawMat2023) , Athens, Greece, 28 August - 2 Septemeber 2023, 2023
Publisher: NTUA
DOI: 10.5281/zenodo.12528631

Linear Programming-Based Approach for Creating Cements from Bauxite Residue. Bauxite Residue Valorization and Best Practices

Author(s): Som, D., Roy, R., Hertel, T., Beersaerts, G., Patrinos, P., & Pontikes, Y.
Published in: TMS 2025 Las Vegas, USA, 2025
Publisher: TMS
DOI: 10.5281/zenodo.18390044

Metallurgical valorization pathways for calcium aluminate slags

Author(s): Vafeias, M., Bempelou, A., Georgala, E., Bagani, M., Mikeli, E., Tsaousi, G. M., Toli, A., Marinos, D., SPARIS, D., Balomenos, E., & Panias, D
Published in: 9th International Slag Valorisation Symposium, 2025
Publisher: KU Leuven
DOI: 10.5281/zenodo.18390247

Thesis and dissertations (1)

Hydrogen-Based Iron Recovery from Bauxite Residue

Author(s): Velle, Sander Ose; Vollan, Frida; Skibelid, Olivia Bogen
Published in: Hydrogen-Based Iron Recovery from Bauxite Residue, Issue 3, 2022
Publisher: NTNU
DOI: 10.5281/zenodo.12516190