Integrated Approaches to Aluminum Recycling: From Conventional Scrap Processing to Bauxite Residue Valorization

Applied Sciences, vol. 16, pp. 8529

Abstract

The growing global demand for aluminum, combined with increasing environmental constraints, has intensified the need for more sustainable production and recycling strategies. While conventional aluminum recycling from scrap is well established and highly energy efficient, a significant fraction of aluminum remains inaccessible in industrial residues such as bauxite residue (red mud). Existing studies predominantly address either scrap-based recycling or red mud valorization separately, with limited integration of these approaches within a unified resource efficiency framework. This paper provides a comprehensive review of aluminum recycling technologies with a particular focus on their role in circular economy strategies, and highlights the emerging importance of secondary resource recovery from red mud. A critical assessment of current recycling technologies is presented, emphasizing key challenges such as impurity accumulation, alloy complexity and process limitations. Furthermore, the paper presents a dedicated comparative analysis of both routes, highlighting their complementarity, their differing levels of technological maturity, and a realistic pathway for their combined implementation within a circular economy framework. In doing so, the study bridges the gap between traditional aluminum recycling and alternative secondary resource utilization, distinguishing this review from prior work that has treated these two domains separately, thereby contributing to the development of more sustainable aluminum production systems.

Authors 5

1. Mile B Djurdjevic corresponding

   University of Applied Sciences Upper Austria

   Affiliation as printed

   Department of Material Science and Technology, University of Applied Sciences Upper Austria, Roseggerstraße 15, 4600 Wels, Austria

2. Srećko R. Stopić corresponding Aachen Institute for Process Metallurgy and Metal Recycling

   RWTH Aachen University

   Affiliation as printed

   Institute for Process Metallurgy and Metal Recycling, RWTH Aachen University, Intzestrasse 3, 52072 Aachen, Germany

3. Miroslav D. Sokić

   University of Belgrade · Institute for Technology of Nuclear and other Mineral Raw Materials

   Affiliation as printed

   Institute for Technology of Nuclear and Other Mineral Raw Materials, University of Belgrade, Franchet d’Esperey 86, 11000 Belgrade, Serbia

4. Željko J. Kamberović

   University of Belgrade

   Affiliation as printed

   Faculty of Technology and Metallurgy, University of Belgrade, Karnegijeva 4, 11020 Belgrade, Serbia

5. Vladimir Damjanović
   Affiliation as printed

   NOVA Alumina DOO, Karakaj b.b., 75400 Zvornik, Bosnia and Herzegovina