Iron Recovery & Valorization
Turning iron-rich residues into clean feedstock for low-carbon steelmaking
PROBLEM: Iron Locked in Waste, Not Rare
Iron is abundant, but in mining and metallurgy it’s often discarded within tailings and mixed feeds, creating massive storage liabilities and lost value.
At the same time, steelmakers need high purity iron ore for low-carbon steel production using the modern DRI method - yet face a looming global shortage.
TENSION: A Global Shortage Meets a Carbon Challenge
Steel contributes ~7% of global CO₂ emissions.
As the industry transitions toward low-emission production, DR-grade iron ore demand is projected to outpace supply by 2–3x by 2030.
Market outlook:
US$31.2B DR-grade market (2022); 8.6% CAGR (2023–2032)
Forecasted 160–200 Mtpy demand vs. 40–100 Mtpy supply
Sources: McKinsey 2021; Midrex 2022; S&P Global 2022.
SOLUTION: Recovering High-Purity Iron from Residues
GEOMEGA’s technology selectively recovers high-purity iron products from mining tailings and industrial waste — delivering feedstock of DR-grade iron ore.
The process operates in a closed-loop, low-effluent design that also allows to capture valuable secondary metals such as Ni, Co, and REE, if present.
KEY ADVANTAGES:
95% Fe recovery, >98% Fe₂O₃ purity
Converts waste iron to DR-grade iron oxide
60% lower CO₂ footprint vs. conventional refining
Polymetallic recovery in one circular process
PROOF: Pilot Validation
Bench-scale testwork confirmed economic recovery from bauxite residue (red mud), REE magnet recycling and other iron rich tailings
Successful piloting at GEOMEGA’s Boucherville facility (Technology Readiness Level, TRL 6–7)
Demonstration scale plant being built for magnet recycling application
Ongoing engineering with Rio Tinto for an on-site demonstration plant from bauxite residue
PAYOFF: Closing the Iron Loop
Recover iron. Reduce waste. Enable low-carbon steelmaking.
Circular metallurgy isn’t a dream — it’s already in production.
Operational: Recover high-purity Fe with near-zero waste; reduce storage liabilities; lower OPEX via closed loop; deploy on-site.
Strategic: Supply DRI market; co-metal revenues; stronger ESG; license or co-develop plants.
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% iron recovery
>Fe₂O₃ purity