irajya

Transforming Red Mud into Industrial Value | Irajya Ecotech
Irajya Ecotech

Transforming Red Mud into Industrial Value

Irajya Ecotech is establishing an industrial proof-of-concept facility at Rayagada, Odisha, to demonstrate a process for the beneficial utilisation of red mud, an industrial residue from alumina production, by recovering iron-rich material for potential use by steel and allied industries.

The Problem

Red Mud: A Large Industrial Residue Waiting for Responsible Utilisation

Red mud, also known as bauxite residue, is generated during alumina production. It is a high-volume industrial residue that creates long-term land, handling and environmental management challenges for alumina producers. Irajya Ecotech’s focus is to convert this residue from a storage liability into a recoverable industrial resource.

Our Solution

Recovering Iron-Rich Material from Bauxite Residue

Irajya Ecotech is developing a process to recover iron-rich material from red mud through a technology route provided by Eesavyasa Technologies Pvt. Ltd. The target product is a Synthetic Magnetic Mineral Composite, or SMMC, with magnetite-like characteristics. The recovered material is intended for evaluation by steel, sponge iron, DRI and allied industries, subject to customer testing, grade validation and market acceptance.

Technology

Patent-Granted Magnetic Carrier Technology

The SMMC process uses Nano Technology Advanced Magnetic Carrier Technology to process red mud through a dry beneficiation route.

1

Red Mud Intake

2

Drying

3

Grinding

4

Blending with Nano-Reagents

5

Magnetic Carrier Reaction

6

Magnetic Separation

7

Pelletisation

8

Dispatch-Ready Product

Phase 1 Plant — Major Equipment

Rotary Dryer Ball Mill Ribbon Blender Magnetic Carrier Reactor Magnetic Separator Pelletising Equipment Dust-Collection Systems Automated Controls Safety Monitoring Devices
The Product

Synthetic Magnetic Mineral Composite

The target product is Synthetic Magnetic Mineral Composite, or SMMC — a magnetite-type iron-rich material recovered from bauxite residue.

95%+
Product purity as Fe3O4 in laboratory and pilot work
60–65%
Iron content range as FeO
SMMC
Magnetite-like characteristics for industrial evaluation

The product is being evaluated for potential use in steel, sponge iron, DRI and allied industrial applications, subject to customer testing, grade validation and market acceptance.

Figures reflect internal laboratory and pilot results and remain subject to third-party validation and customer acceptance.

By-Products & Future Recovery

Beyond Iron Recovery

Alongside the iron-rich SMMC product, the process yields a secondary mineral stream described as enriched alumina with titanate. Future R&D may evaluate titanium-bearing fractions and other mineral streams where technically and commercially viable.

Rayagada • Odisha

Industrial POC at Rayagada, Odisha

Irajya Ecotech is establishing an industrial proof-of-concept facility at Rayagada, Odisha. The POC is aimed at demonstrating an industrial process for beneficial utilisation of red mud by recovering iron-rich material that can potentially be used by steel and allied industries.

The project is also expected to support local industrial activity, direct and indirect employment, skill development, local vendors and service providers, and environmentally responsible resource recovery in the district.

Benefits

Environmental and Industrial Benefits

Supports beneficial utilisation of a high-volume industrial residue.

Creates a pathway to recover iron-rich material from red mud.

Supports circular economy and resource efficiency in alumina and steel-linked value chains.

Can create local employment, vendor opportunities and skill development around the Rayagada POC.

Provides a platform for further industrial validation, scale-up and strategic partnerships.

Partnership Opportunities

Who We Work With

Irajya Ecotech welcomes discussions with:

Alumina Refineries

Seeking responsible red mud utilisation pathways.

Steel, Sponge Iron & DRI Producers

Evaluating alternative iron-rich feedstock.

Industrial Groups

Interested in circular economy and mineral recovery.

Government Agencies

Focused on industrial waste utilisation and local development.

Strategic Investors & Partners

Interested in scaling resource-recovery infrastructure.