ADVANCED RECYCLING AND REUSE OF METALLURGICAL WASTES FOR SUSTAINABLE MATERIALS PROCESSING

Abstract

Metallurgical wastes recycling and reuse have emerged as the window to achieving sustainable material processing and implementing circular economy practice. The research uses a systematic review approach adhering to the PRISMA protocol to aggregate information from 78 peer-reviewed journals over the years 2015 to 2025. The review classifies metallurgical wastes into steel slags, tailings, red mud/bauxite residues, and metallurgical dusts and sludges and examines their valorisation as construction materials, resource recovery techniques, and innovative functional products. Findings show construction reuse, representing 41% of the studies reviewed, as having extensive substitution potential with up to 60% for cement and concrete uses combined with up to 25% CO₂ saving potential. Resource recovery routes, representing 38% of the reviewed works, have provided high-value extraction yields of 70–95% for base metals but are constrained by high reagent and energy requirements. Use of high-technology materials, which contributed just 21% to the research, had significant scope towards evolving geopolymers and high-performance composites with enhanced mechanical and environmental performance. Comparative evaluation indicates that the use in construction is the most advanced, recovery of resources holds the maximum economic potential, and development of advanced materials is closest to long-term sustainability targets but needs increased industrial adoption. The results highlight the imperative of effective, sustainable, and scalable recycling strategies to maximize environmental, technical, and economic efficiency in metallurgical waste valorisation.