Laterite and its potential as an alternative-bauxite

•Selective acid leaching of Al and Fe from laterites.•Al extraction from laterites as an alternative for bauxite.•Corundum nanoparticle production from laterites. Aluminium-related materials play a significant role in the current industrial applications, including metallurgy, ceramics, medicine, dentistry, automobile, and construction. Al is extracted from bauxite ore which will be extinct sooner than expected as the demand for Al is ever-increasing. Thus, a low-grade alternative ore called laterite was used for the production of Al-related advanced materials. The process includes the optimization study of the element extraction from laterites, followed by utilizing the extract to produce sustainable, energy-saving advanced materials. The ultimate outcomes of the process are the synthesis of alumina powder and its advanced materials by a cost-effective and industrially viable method. The products were characterized by several microscopic and chemical tests, which revealed the alumina powder contains a mixture of corundum and θ-Al2O3 and nano-sized alumina had nano-spherical morphology having corundum structure. This process is a highly sustainable and energy-saving process than the conventional production of Al-related materials and the cost for the production of these materials is less. Hence this study is a successful attempt in utilizing laterites as an alternative for bauxite, and the products can be used for many nano-technological applications which will give rise to many new-age industries and startups.