ReActiv: A Win-Win Scenario for the European Alumina Refineries and the Cement Industry
Context
Processed bauxite—also known as bauxite residue or red mud—is the main by-product generated by alumina refineries alongside alumina, which is a key material for primary aluminium production. The cumulative stockpile of processed bauxite in Europe currently exceeds 250 million tonnes (dry basis). Globally, the inventory could reach 10 billion tonnes by 2050, particularly if reuse rates do not significantly improve. Currently, only 3% of the processed bauxite generated worldwide is valorised.
At the same time, traditional Supplementary Cementitious Materials (SCMs) such as fly ash and ground granulated blast furnace slag are becoming increasingly scarce due to the decarbonisation of the energy and steel sectors. As a result, the cement industry is seeking alternative materials to support its circularity and decarbonisation goals. The availability of processed bauxite and the proximity of alumina refineries to cement plants across Europe present a promising opportunity for resource efficiency and circularity through industrial symbiosis.
ReActiv: A SPIRE cPPP Project
Proposing a breakthrough approach that links European alumina refineries with the cement industry, the ReActiv project (full title Industrial Residue Activation for sustainable cement production) aimed at turning an industrial residue -processed bauxite- into a valuable resource for low-CO2 cement products. The Innovation Action (IA) was funded by Horizon 2020, under a call of SPIRE cPPP (the predecessor of Processes4Planet), kicked off in November 2020 and concluded in April 2025, involving 23 partners (of which five SMEs) from 12 countries.
ReActiv specifically established a symbiotic value chain between cement plants and alumina refineries by demonstrating the conversion of processed bauxite into Supplementary Cementitious Materials (SCMs). This SCM was shown to be suitable for low-CO2 cement production by substituting up to 30% wt% of clinker (the main ingredient in cement) during production. In doing so, ReActiv proposes a ‘win-win scenario’ for both industrial sectors: reducing industrial residue volumes and cutting CO2, as the project’s website explains.
Goals and Vision
To achieve its ambitious goals, the project relied on the parallel investigation of three different processing routes: processed bauxite thermal activation with kaolinite clay (co-calcination process), processed bauxite carbothermic vitrification for iron-rich SCM (vitrification process) and processed bauxite reductive smelting for iron-free SCM (smelting process).
Furthermore, the project demonstrated the direct use of processed bauxite in two new alternative cement products: A novel calcium sulfoaluminate-ferrite (CSAF)-clinker that uses 35 wt.% of processed bauxite as raw material (related to the vitrification process) and a novel calcium aluminate cement (CAC) produced concurrently with metallic Fe via processed bauxite smelting (related to the smelting process).
The Success Story
A Replicable Technology with High Potential for CO₂ Emissions Avoidance
The three demonstrators developed during the project are up and running, representatives of ReActiv informed us.
The ReActiv Life Cycle Assessment by Imperial College London estimates that the 100-year Global Warming Potential (GWP100) for ReActiv supplementary cementitious materials (SCMs) ranges from 200 to 470 kg CO₂ per tonne, depending on the processing route applied. Lowering the climate impact of ReActiv’s SCMs can also be achieved by transitioning to green electricity for processing operations and employing biocarbon in place of conventional fossil-based reducing agents.
By enabling the valorisation of processed bauxite, the ReActiv innovation offers an alternative to conventional storage methods. As a result, it can lead to measurable reductions in water consumption and contribute to more sustainable residue management.
ReActiv drives sustainable societal impact by fostering green-skilled jobs, gender-balanced leadership, and a circular economy through low-carbon industrial innovation.
The Coordinator’s Angle
Asked about what makes ReActiv a success story, Philippe Benard of Holcim (the project coordinator) says that ‘ReActiv transforms an abundant industrial residue into a valuable resource, enabling true industrial symbiosis. It has redefined perceptions around processed bauxite, catalysed cross-sector collaboration, and set a scalable blueprint for resource efficiency/circularity, accelerating the cement industry’s decarbonisation and reshaping waste/by-products valorisation pathways in Europe in an environmentally safe and financially viable way. The project’s outcomes are in line with the EU Clean Industrial Deal and act as an enabler to a more sustainable future for Europe.’
A.SPIRE considers ReActiv a success story exemplifying how cross-sectoral collaboration and circular innovation can transform industrial residues into valuable resources, fostering environmental, economic, and societal benefits. By advancing scalable, low-carbon cement solutions, reducing waste, and promoting green-skilled employment with inclusive leadership, ReActiv aligns strongly with EU climate and industrial objectives and the Processes4Planet SRIA 2050.
Download the leaflet for more information about this success story.
Visit the ReActiv project’s website.
For more information about A.SPIRE, the Processes4Planet Partnership, and the Success Stories, contact the team.
