Bauxite Research Articles

Geological Features and Ore Formation Pattern of Jinzhong Bauxite Mine, Shanxi Province, China

Bauxite is located in the lower part of the Benxi Formation, and the prospecting project shows that the distribution of bauxite ore bodies in the area is discontinuous, and there are differences in the thickness of the ore bodies. To have a clearer understanding of the bauxite ore bodies and metallogenic pattern in the census area, this study has made use of the prospecting project data, sample analysis results, etc., and combined with the geological and tectonic background of the area, the stratigraphic spreading characteristics of the bauxite ore body spatial spreading, ore characteristics and ore controlling factors in the area have been explored and researched. The bauxite ore bodies in the study area are stratified but the ore-bearing rock system is influenced by the Ordovician paleokarst geomorphology and intermittently distributed horizontally, which can be distinguished into three different ore bodies. The bauxite ore body and Shanxi-style iron ore are associated with hard clay ore, in which the ore minerals are mainly monohydrate duralumin. The natural ore type can be divided into dense bauxite and oolitic bauxite. Bauxite in this area mainly originated from the basal Ordovician carbonate rocks, with a combination of iron-rich and aluminum-rich layers, and is a typical carbonate rock sedimentary deposit of ancient weathering crust.

The Middle-Late Permian Yakshawa and Late Cretaceous Daresard bauxite deposits, western Iran: Elemental deportment, parental affinities and genesis of REY minerals

The Middle-Late Permian Yakshawa bauxite deposit in the Sanandaj-Sirjan Zone and the Late Cretaceous Daresard bauxite deposit in the Zagros Fold-Thrust Belt have bauxite ores with different textures and mineralogical compositions. The presence of detrital and authigenic REY-phosphates, fluorocarbonates of the bastnasite group, and cerianite with diverse generations reflect an intricate formation process of the REY-bearing minerals in these two deposits. This clearly shows that the studied deposits have a multi-stage evolution including diagenetic and/or low-grade metamorphic, in situ fluid-assisted dissolution–reprecipitation reactions, and later bauxitization. The high abundance of monazite, textural relationships, and its LREE pattern indicate this mineral is the main LREE reservoir in the studied bauxite ores whereas xenotime, both authigenic and detrital, is the main host for HREE. The R-mode factor analyses indicates that the bauxitization process induces, at large, similar interelemental relationships in the studied deposits involving the attitude of Al oxyhydroxides, Ti oxides, and Fe oxyhydroxides to concentrate critical metals and the capability of REY-phosphate of being the main reservoir of REE + Y. As for provenance, the Eu/Eu*, Sm/Nd, and Nb/Ta proxies suggest that the bauxite ores of the Yakshawa deposit have a genetic relationship with Middle-Late Permian mafic volcanic rocks, whereas the ores of the Daresard deposit show parental affinity with the underlying fine-grained clayey limestone of the Sarvak Formation.

Understanding Trace Iron and Chromium Incorporation During Gibbsite Crystallization and Effects on Mineral Dissolution.

Incorporation of pollutants, e.g., heavy metals, or critical elements, e.g., lithium, as impurities in mineral phases can significantly affect their mobility or sequestration in the environment. Even when present at low concentrations, impurities can alter the solubility and reactivity of the host mineral. In this study, we investigate the incorporation of trace amounts of iron (Fe3+) and chromium (Cr3+) during the crystal growth of the aluminum (Al3+) hydroxide, gibbsite, a major component of bauxite ores, an important soil mineral, and a dominant mineral phase in stored radioactive wastes. Using a comprehensive suite of analytical techniques, we show that both Cr3+ and Fe3+ can be incorporated into the gibbsite lattice during coprecipitation by replacing Al3+ in octahedral sites. These small amounts are consistent with limited to no structural isomorphism shared between Al3+ and Cr3+/Fe3+ hydroxide precipitates, nor room temperature miscibility of their isostructural M2O3 oxide forms, in contrast with oxyhydroxide forms where Al3+ and Fe3+ share similar structural topologies. Despite the limited uptake of Cr3+/Fe3+, we show that these impurities have significant implications for gibbsite dissolution behavior. The limited uptake of Cr3+/Fe3+ (e.g. 0.43% Cr3+ and 0.4% Fe3+), we show that these impurities have significant implications for gibbsite dissolution behavior and subsequent reactivity in complex environments.

Land, Forest, Adivasis, and the Making of New Resource Frontiers

This article examines the growing bauxite mining activities aimed at extracting aluminum ore in the Netharhat Valley, located in the Gumla and Latehar districts of Jharkhand. Adivasis share an inseparable relationship with land and forest, which play a vital role in shaping their identity and social structure. However, the introduction of new mining frontiers has ushered in persistent extraction challenges in Adivasi’s life. Although capitalist varied interests promise Adivasis for development imperatives and their chance to uplift themselves through mining, the outcomes are both complex and multifaceted. The current situation is marked by complexity as the introduction of the new mining frontiers has skewed the balance. The article illustrates the diverse consequences of extensive mining on the Adivasis and their diminishing control over land and forests. It illustrates the varying stances on the issue of mining, and their differing opinions have created divisions among the villagers based on class, economic priorities and market opportunities. The introduction of new resource frontiers has weakened village egalitarianism and institutions, allowing for mining capitalism to penetrate the Adivasi heartlands.

Extraction of Aluminum Oxide from Local Kaolin Clay Deposits in Ethiopia

The need for aluminum is growing worldwide, which has sparked interest in finding alternate ways to make alumina from materials other than bauxite, particularly clays. This article examines the use of sodium carbonate as a leaching agent in the lime sintering process to recover alumina from kaolin. Excavated from Tarmaber, Ethiopia, kaolin clay contains a content of 32.88%, which has a relatively good composition. Collecting and grounding raw kaolin to micrometer-level particle size is the first task. The recovery of kaolin alumina was studied at sintering temperatures of (T<sub>1</sub>=800°C, T<sub>2</sub>= 900°C & T<sub>3</sub>=1000°C) at different sintering times of (t<sub>1</sub>=1 hr, t<sub>2</sub>=2 hrs & t<sub>3</sub>=3 hrs). After the raw material was burned at the given temperatures and times, it was cooled for the night in the furnace and leached with different concentrations of sodium carbonate (M<sub>1</sub>=50 g/l, M<sub>2</sub>=60 g/l & M<sub>3</sub>=70 g/l). The response surface methodology (RSM) in combination with the central composite design was used to optimize the operating parameters. The optimization result shows that the optimal conditions were a calcination temperature of 953.84°C, a sintering time of 2.99 h, and a leaching agent concentration of 70 g/l. At this optimal condition, the yield of Alumina was 1.05 g of 20 g of Kaolin clay. The resulting Alumina was crystalline in structure (from XRD analysis), contains 89.05% Al<sub>2</sub>O<sub>3</sub> (from silicate analysis) and a large broad band between 400-1000 cm<sup>-1</sup> is attributed to Al-O-Al stretching of Alumina (from FT-IR analysis). So, it is possible to conclude that alumina production from no bauxite ores is possible.

Application of ultrasound for leaching Vietnamese monazite concentrate with NaOH solutions to obtain chlorides of rare earth elements

Relevance. Despite the use of alkali stripping technology for processing monazite concentrate in industry, this method has a number of limitations, such as low efficiency of concentrate stripping, the need to use a large excess of alkali and a long process time. Aim. Improvement of existing technology to overcome these limitations. Methods. Fusion with NaOH under pressure and fusion with NaOH combined with ball milling, as well as fusion with NaOH using high intensity ultrasound. High-intensity ultrasound has long been studied and used in industry to intensify leaching/alloying in various applications to increase efficiency and speed in leaching for copper, vanadium, nickel, bauxite and uranium ores. This article is devoted to studying the influence of high-intensity ultrasound on the efficiency of opening monazite concentrate with NaOH solutions. Experimental data were obtained using mass spectrometric, X-ray diffraction and ICP-OES analysis methods. Results and conclusions. The optimal conditions for leaching batches of samples weighing from 100 g to 1 kg were determined. The authors have carried out the research on the separation of radioactive elements and impurities in a solution of rare earth chlorides, obtaining a solution of rare earth chlorides purified from radioactive components and impurities. It was shown that ultrasonic exposure eliminates the disadvantages of traditional fusion technology with NaOH, which can be used for deep processing of Vietnamese monazite concentrate. The conditions for obtaining REE chlorides from a previously opened monazite concentrate are given.

Development and sustainability assessment of red mud-based green bricks: Techno-economic and environmental performance

Red mud (RM) is an alkaline discarded hazardous waste for mining alumina from bauxite ore and thus has the potential to be used for geopolymerization. This work has been designed to couple RM with by-product waste to develop a green structural block, an alternative to fired clay or cement brick. Specimens were initially prepared at a lab scale for optimization and thus verified at an industrial scale. At the lab scale, the proportion of RM was optimized by using it in the range of 0–50 % at 10 % intervals and activated by the combination of NaOH and Na2SiO3. The physico-mechanical performance was evaluated, and the specimen with 30 % RM performed best at ambient and hot curing conditions. Upon transitioning to an industrial scale, structural block/brick measuring 225 × 113 × 75 mm was manufactured using uniaxial compression, resulting in a notable 202 % increase in strength compared to laboratory-scale specimens. Furthermore, blocks/bricks fulfilled the structural requirements outlined by ASTM and ACI, validating their suitability for industrial applications. Economic and environmental analyses of developed bricks revealed fewer costs and significantly lower CO2 emissions than conventional bricks and geopolymer-based bricks. The economic and environmental indices also made the RM the appropriate choice. Furthermore, the RM-based brick is sustainable and feasible based on the sustainability matrix.

A Comparative Study to Assess the Efficiency of Wet Beneficiation Techniques for Treatment of Low-Grade and High-Grade Bauxite Ore

A Comparative Study to Assess the Efficiency of Wet Beneficiation Techniques for Treatment of Low-Grade and High-Grade Bauxite Ore

Compound criticality of bauxite production: implications for sustainability and trade neo-colonialism

We describe bauxite as having compound criticality. (1) It is a critical raw material (CRM) from which alumina and thereby aluminium are produced, and aluminium has the highest production levels of all metals deemed significant to the Clean Energy Transition. (2) Gallium is a by-product CRM, extracted during alumina refining. (3) Multiple other CRM by-products could be extracted during alumina refining: scandium, lithium, cobalt, titanium and REE. (4) Production is profoundly influenced by price inelasticity (for by-products), regime instability of bauxite production and supply chain bottlenecks. We review the geology of bauxite ore deposits as a function of complex CRM supply potential, and interrogate the trait of criticality using four of the world's dominant producer nations of bauxite and potential patterns of value addition from raw materials to refined products. Trade agreements and mitigation strategies to ensure security of supply in consumer regions prioritize removal of low-cost bauxite by large-scale mining operations and shipping of unprocessed ore at high CO 2 footprint from producer nations. Ore-refining nations have investments that are deemed extractive because they remove large quantities of raw material for export with minimal or no in-country processing and they can also place producer nations in debt. Opposition to neo-colonial debt-trap policies and extractive practices increases regime instability and thereby criticality. We highlight how societal-environmental-political interactions and the mineral-energy nexus in the bauxite-aluminium supply chain are subject to increasing turbulence, which may reshape the geographies of supply chains.

Investigation of the possibility of using depleted bauxite in alumina production at the Pavlodar aluminum plant

The topic of processing low-grade or low-quality bauxite is highly relevant in modern conditions due to the gradual depletion of high-quality bauxite reserves. Consequently, there is an increasing need to explore alternative sources of raw materials for aluminum production and its derivatives. Processing low-quality bauxite ores can become an effective solution, reducing dependence on limited high-quality resources and ensuring production stability in the long term. Such research has significant potential for developing technologies capable of optimizing aluminum production processes and enhancing its competitiveness in the global market. Bauxites from the Krasnooktyabrsky bauxite ore management with low aluminum oxide content (37 – 40% by mass) and a silicon module up to 2.0 are considered as potential blending materials for sintering bauxite in alumina production due to the depletion of high-quality bauxite reserves. This article presents the results of research on their processing into alumina at the Pavlodar Aluminum Plant. Laboratory and pilot-scale studies were conducted to assess the feasibility of using low-quality bauxite in alumina production and to determine the techno-economic indicators of processing. The research results confirmed the technological feasibility of processing depleted bauxites with a silicon module of 1.95 - 2.0 in the sintering section while maintaining the quality of sinter and extracting useful components. The maximum proportion of blending of depleted bauxites with the main bauxite was determined not to exceed 50%.

Red mud treated with KOH: synthesis of sustainable materials from waste for water treatment.

Solid waste resulting from bauxite ore (red mud) was converted into useful products consisting in hydrogarnet together with zeolite. Red mud (RM) transformation from disposal material into new source was carried out using potassium hydroxide as an activator and hydrothermal process (HY) or vapor phase crystallization (VPC) approach. HY process was performed at 60, 90, and 130°C whereas during the VPC method, red mud was contacted only with vapor from the distilled water heated at 60 and 90°C. The results indicate the formation of katoite and zeolite L (LTL topology) with both approaches. All the synthetic products display magnetic properties. In addition, a preliminary investigation on arsenic removal from drinking water (from 59 to 86%), makes the synthetic materials appealing for environmental applications. Finally, the synthesis of a large amount of very useful newly-formed phases using vapor molecules confirms the efficiency of the innovative and green VPC process in waste material transformation.

Genesis of Carboniferous aluminous-bearing strata in the northern part of the North China Craton: A case study of the Xingxian bauxite deposit

More than five billion tons of karstic bauxites were formed in the North China Craton (NCC) during the Late Carboniferous period. Compared to the bauxite ore, the genesis of the entire aluminous-bearing strata has received less attention. In this study, we conducted geological, mineralogical, and geochemical analyses on core samples from the aluminous-bearing strata located in Xingxian area, situated within the northern NCC, aiming to elucidate the genetic process of these formations. The aluminous-bearing strata consist of a bauxite layer (diaspore–anatase–kaolinite–florencite) sandwiched between the upper sandy claystone horizon (kaolinite–illite–quartz) and the lower berthierine-bearing claystone horizon (berthierine–diaspore–hematite–goethite). Based on the upper continental crust-normalized patterns of rare earth elements and yttrium (REY), immobile trace element ratios, mineral inheritance diagrams, and previous findings, it is suggested that the lower berthierine-bearing claystone was weathered from the impure limestone at the bottom, whereas the upper bauxite and sandy claystone mainly originated from intermediate-felsic igneous rocks of the northern margin of the NCC, granite from the North Qinling Orogenic Belt, and aluminosilicate rocks of the surrounding paleo-uplifts. During the early diagenetic stage, the berthierine was transformed under alkaline and reducing conditions from iron-rich clays (composed of clay minerals, ferric minerals, etc.) formed in acidic and oxidizing conditions from the underlying impure limestone. The coexistence of berthierine with low-temperature stability and diaspore is observed in the berthierine-bearing claystone, which precludes a high-temperature origin of diaspore in the aluminous-bearing strata. Moreover, diaspore is characterized by a small crystal size and is usually poorly crystallized, suggesting a supergene precipitation-diagenesis origin. The paragenetic minerals assemblages (e.g., diaspore, berthierine, goethite, hematite, etc.) suggest that the aluminous-bearing strata primarily formed in a transition zone nearer to the phreatic environment. Large-scale volcanism and warm, humid climatic conditions accelerated the decomposition of allochthonous weathering materials, resulting in the downward migration of metal ions. These ions then precipitated in a reducing and weakly alkaline environment, giving rise to form bauxite ore dominated by diaspore, anatase, and REY minerals.

Auxiliary collector optimizing foam characteristic and adsorption behavior towards efficient flotation desilication of bauxite

The desiliconization of bauxite through flotation poses challenges due to the limitations of conventional collectors like oleic acid. Hence, there is an urgent need to explore more selective alternatives to enhance efficiency. In this study, sodium dodecyl sulfate (SDS), sodium dodecyl sulfonate (SLS), and benzohydroxamic acid (BHA) are explored as auxiliary collectors with sodium oleate (NaOL) to enhance its efficiency and selectivity. Bench-scale tests reveal that combined collectors exhibit superior flotation efficiency and concentrate quality compared to NaOL alone, both in laboratory settings and actual bauxite ores. Detailed mechanistic insights are provided from both macroscopic and microscopic perspectives. Macroscopic analyses uncover differences in foam and pulp properties among the combined collectors, indicating that the NaOL + BHA system offers moderate foaming performance, stability, and homogeneity, enhancing collection efficacy and selectivity. Microscopic investigations elucidate the adsorption mechanism between combined anionic collectors and mineral surfaces using the quartz crystal microbalance with dissipation (QCM-D) and Fourier transform infrared spectroscopy (FTIR). QCM-D analysis shows that SDS, SLS, and BHA weaken NaOL adsorption on kaolinite surfaces and accelerate reagent desorption, with BHA having the most significant effect. These findings provide valuable insights for optimizing bauxite flotation processes with improved efficiency and selectivity.

Overview on Hydrometallurgical Recovery of Rare-Earth Metals from Red Mud

Aluminum is produced from its primary bauxite ore through the Bayer process. Although Al is important nowadays in the development of humanity, its production leads to the generation of a huge amount of waste, called red mud. Globally, the estimation of the stock of red mud is about 4 billion tons, with about 10 million tons located in Turkey. The presence of rare-earth elements (REEs) in crucial materials such as red mud makes it a major source of these elements. A number of methods have been developed for treating red mud, which are employed globally to recover valuable products. The application of a suitable method for REE extraction from red mud is a way to overcome the supply risk, contributing to reducing the environmental issues linked to red mud pollution. The current review summarizes the research on red mud processing and examines the viability of recovering REEs from red mud sustainably, utilizing hydrometallurgy and biohydrometallurgy.

Integrated management of abatement technology investment and resource extraction

As the need for increased renewable energy generation to meet climate goals grows, so does the demand for critical minerals in the industrial sector. This raises concerns about the availability of supply and the reliability of investment in critical minerals. Based on this, the study proposes an analytical framework for the integrated management of mineral extraction and renewable energy investments. Different from the previous strategy of separate management, this study has established an integrated model that utilizes new energy technology as the downstream application of emission reduction technology. It also utilizes copper, zinc, aluminum, rare earth elements, and other materials as the upstream raw material supply. In terms of minimizing costs, the entire supply chain process is optimized to achieve an empirical case. In addition, considering the significant uncertainty in the process of reducing emissions from new energy technologies, this study also incorporated a forward control stochastic programming method to model and solve it. We obtained confidence intervals for optimal technological investment paths and metal mining paths under various scenarios. Our findings indicate that: (1) Biomass, as a renewable energy technology with the lowest resource demand, should be prioritized for development. However, there is significant uncertainty surrounding the installed capacity of photovoltaics. (2) Copper ore reserves have little impact on the development of renewable energy technologies, while zinc ore and aluminum ore have a greater impact on wind energy and photovoltaics, respectively. (3) By optimizing the cut-off ratio of raw ore under a specific amount of ore storage, we can ensure the availability of materials needed for downstream energy technology.

Geochemical constraints on the Gano karst bauxite deposit, eastern Alborz Mountains, northern Iran: Implications for provenance, elemental mobility, and distribution of critical metals

The Gano karst bauxite deposit is located in the eastern Alborz Mountains, 90 km NE of Semnan city, northern Iran. The layers and lenticular patches of bauxite are hosted in the Triassic karstified carbonate rocks interbedded with calcareous shale of the Elika Formation, unconformably overlain by siliciclastics of the early Jurassic Shemshak Formation. The bauxite ores have a mineral assemblage dominated by diaspore and hematite, with lesser kaolinite, illite, chlorite, goethite, anatase, dolomite, and quartz. In the Gano area, intrusions range from monzonite to quartz monzonite in composition with an alkaline composition that generated in an extensional regime within a plate tectonic setting. Geochemical signatures of the Gano bauxite ores suggest a derivation from the monzonite intrusions at the base of the Elika Formation, although a contribution of interbedded calcareous shale of the Elika Formation cannot be excluded. Based on the variation of Ce anomaly across the studied profile and the integration of petrographic evidence and mineralogical and geochemical data, the Gano deposit formed in an oxidized environment under warm-humid climates, significantly linked to rainfall seasonality and groundwater-level fluctuations. Gallium, Nb, and V median values of the Gano bauxite ores are a bit above the maximum value of these critical metals in the northwestern Iranian and Alborz bauxite data set, making diaspore-, anatase-, and hematite-rich layers and lenses valuable for further exploration of these critical metals.

Simulation study on basic road performance and modification mechanism of red mud modified asphalt mixture

Abstract In order to study the basic road performance and the mechanism of red mud modified asphalt, Marshall test, rut test, freeze-thaw splitting test, and immersion Marshall test were carried out for matrix asphalt mixture and red mud modified asphalt mixture, and molecular simulation technology was introduced to study the mechanism of red mud modified asphalt. The results showed that the penetration rate of red mud modified asphalt was lower than that of the matrix asphalt, and the softening point of asphalt was significantly improved after the addition of red mud, and the mixing of red mud reduced the asphalt ductility greatly. The intensity ratio (test strength ratio; TSR) of the freeze-thaw test of red mud modified asphalt under 3, 5, 7, 9, and 11% was increased by 13.18, 11.22, 13.54, 12.01, and 8.45%, respectively, compared with the matrix asphalt mixture, and the dynamic stability value increased by 127.23, 176.87, 200.99, 96.23, and 12.95%; the residual stability value of the immersion Marshall test increased obviously. Generally, the research of red mud modified asphalt is quite worthy, it can solve the problem of aluminum ore slag and reuse of resources, and provide a new way to extend the industrial chain.

Genesis of Bauxite Ore in Toba Area Sanggau District, West Kalimantan Province

Indonesia's largest bauxite reserves are in the province of West Kalimantan, which is 703 million tons Bauxite is formed from rocks with a high relative aluminum (Al) content, low iron (Fe) content, and small amount of quartz. The mineralogy and characteristics of lateritic bauxite deposits are closely related to several factors, one of which is the texture and composition of the bedrock such as color, mineral composition, and shape of the ore. This study discusses the genetic type of bauxite deposits based on mineralogy and geochemistry using mineragraphic, XRD, and XRF methods. The primary data from bauxite ore samples were collected from the stockpile of PT. Dinamika Sejahtera located in Toba area. The quantitative result of the geochemical analysis indicates a higher amount of alumina observed using the XRF method. Granodiorite bauxite, which is bauxite coming from granodiorite bedrock, generally has abundant geochemical elements, especially SiO2 and Al2O3. The lateritic bauxite type in the Toba area is a product of granodiorite weathering from the Sepauk Tonalite formation is embedded within a clay matrix which exhibits a brownish to red color with coarse to boulder-size of concretion texture without relict. Some important elements in bauxite laterite deposits are Al, Fe, Si (Silicon), and Ti (Titanium). The comparison between Al and Si values is a benchmark for the economics of bauxite mines. Gibbsite is the major mineral in the bauxite ore, while hematite, goethite, kaolinite, and quartz are the accessory minerals. The deposit is recognized as Low-Fe bauxite due to comparing Al2O3, Fe2O3, and Si2O3 concentrations. The weathering process has altered the primary texture, remaining resistant and secondary minerals. The petrographic analysis shows the replacement of Gibbsite as bauxite ore which presents as kaolinite replacement and fills the mineral cracks. The result of this study is expected to be useful in determining the exploration method for the bauxite deposits.

SYNTHESIS OF ALUMINA FROM KAOLIN FOUND IN AJEBO, OGUN STATE, NIGERIA

This study proposes the utilization of kaolin as an alternate resource for alumina production due to the decreasing availability of bauxite ores in Nigeria. This project covers the procedures and operations required to produce a high surface area γ-alumina using kaolin, a refractory material. The kaolin used in this study was sourced from Ajebo in Ogun State, Nigeria. The mineral processing of kaolin was the initial step involving removing inherent impurities from the clay. Subsequently, calcination was performed to eliminate crystallised water and impurities and activate the kaolin's limited alumina content. This activation process facilitated the subsequent acid-leaching reactions. At 90oC, 5M HCl acid was used to leach meta-kaolin, which was then filtered. The filtrate was mixed with 5M NaOH at 900oC and was transformed into sodium aluminate. This reaction also facilitated the removal of magnesium and iron hydroxides. Subsequently, HCl was introduced to adjust the pH of the solution. The resulting aluminium hydroxide was then calcinated at temperatures of 700oC and 900oC for 2 hours each to produce γ-alumina. Ultimately, the calcined material was cooled to ambient temperature inside the furnace. The produced γ-alumina was further characterised using X-ray Fluorescence (XRF), Fourier Transform Infrared spectrometer (FTIR), and Scanning Electron Microscopy (SEM).

The Beneficial Effect of Iron in Aluminum-Cerium-Based Cast Alloys

Iron (Fe) has been considered a major impurity since it is detrimental to the mechanical properties of many cast aluminum alloys due to the formation of Fe-containing brittle intermetallic phases. Fe is found naturally as an impurity in bauxite ore, resulting in Fe contamination of aluminum alloys with increasing contamination from current recycling practices. The Al–Ce–Fe system was investigated using CALPHAD (CALculation of PHAse Diagrams) modeling and experimental casting techniques. It was found that additions of Fe to the Al–Ce system are beneficial to the strength (slightly) and ductility (significantly) of the ternary alloys, which is attributed to the formation of fine metastable Al8CeFe2 phase with aggregate morphology and equilibrium Al10CeFe2 phase, suppressing coarse proeutectic Al11Ce3 phase in near-eutectic Al–Ce alloys. Heat treatment study showed that the metastable Al8CeFe2 phase transforms to predicted equilibrium Al10CeFe2 phase at 500 °C, with essentially no intermetallic or grain coarsening; thus, the alloy displayed excellent property retention. The Al–Ce–Fe alloy system offers opportunities for sustainable, recyclable alloy development using low-cost Fe and low-cost cerium (a byproduct of rare-earth extraction).