Wehrli, J., Campbell, M., and Fergusson, L. A Zero Waste Framework for a New Minerals Industrial Complex. Travaux: Du Comité International pour L’étude des Bauxites, de L’alumine et de L’aluminium (ICSOBA), 2011, 36(40), 176-187. Paper also presented to International Seminar on Bauxite Residue, International Committee for the Study of Bauxite, Alumina and Aluminium, Goa, India, October 17-19, 2011. A Zero Waste Framework for a New Minerals Industrial Complex Juerg Theodor Wehrli 1 , Michael Campbell 1 and Lee Fergusson 2 1) HATCH Associates Ltd, Australia 2) Virotec Global Solutions Pty Ltd, Australia Abstract A consortium of companies is in the process of building a 1.8 Mt/year alumina refinery in a new Minerals Industrial City (MIC) in the Middle East. Facilities at the MIC include an aluminium complex, consisting of the alumina refinery, a boiler house, residue storage area, an aluminium smelter and a rolling mill. The MIC also includes a phosphate complex, including a sulfuric acid, phosphoric acid, ammonia and a di-ammonium phosphate plant, plus a captive power plant, a desalination plant, workers accommodation, village and recreational areas. It is estimated that the alumina refinery will produce about 2.0 Mt/year of red mud residue or Alumina Refinery Residue (ARR) and it is understood that the current proposal for managing ARR is dry stacking/natural evaporation. Hence the ARR will be highly caustic with a pH >13 and therefore will need to be safely stored in a designated containment area. There are substantial problems associated with the storage of untreated ARR, and the costs of managing and maintaining the residue storage facilities, public liability insurance, environmental protection, remediation and closure are high. The ARR produced is estimated to contain more than 50% of Desilication Product (DSP). The DSP has been shown to have excellent inherent acid neutralising and moisture retention properties as well as many other beneficial characteristics, including metal binding, phosphate binding and odour abatement. Hence, the ARR produced are potentially a valuable raw material for use in a wide range of applications, including Flue Gas Desulphurisation (FGD), treatment of acidic waste streams, treatment of communal waste, and application as soil improvement for agriculture. The purpose of this study is to investigate the opportunity to utilize the beneficial properties of ARR and to develop and implement a “Zero Waste Framework” for all the facilities located within the MIC. Keywords: Red Mud; Alumina Refinery Residue; Neutralisation; Re-Use; Zero Waste; Sustainability.