Abstract: There are large amount of refractory iron minerals in red mud produced in the production of Al₂O₃ by Bayer Process.Efficiently recovering these iron minerals not only better recover the resources but also is beneficial to reduce the pollutant emissions.High-intensity magnetic pre-concentration-deep reduction-low-intensity magnetic separation process was conducted on the Bayer Process red mud(39.42% Fe) from Shandong.The results indicated that the high intensity pre-concentration concentrate with iron grade of 52.89% and recovery of 59.85% was obtained with grinding fitness of 80.75% -0.074 mm and background field intensity at 1.2 T；With bituminite dosage of 24.27% (mass ratio of bituminite to high intensity pre-concentration concentrate)，reduction temperature 1 300 ℃ for 45 min，reduction product grinding fineness of 38% -0.074 mm and low intensity magnetic field intensity at 72.03 kA/m，the iron powder with iron grade of 91.25% and magnetic separation recovery of 96.90% (General iron recovery of red mud was 57.99%) was obtained.The experimental defined process was simple，stable and reliable and had high industrial application values.

Key words: Bayer process red mud, High-intensity magnetic pre-concentration, Deep reduction, Low-intensity magnetic separation, Iron powder