India is pioneering a major leap for both its tech industry and sustainable manufacturing, turning a challenge like aluminum waste into a resource through innovative recycling technologies.
Chennai-based Entity 1 Value Emissions Pvt. Ltd. announced a breakthrough: the production of semiconductor wafers using silicon from red mud. Red mud is a byproduct of aluminum production. The company claims this makes India the first country to produce wafers from this industrial residue.
The innovation is a key step toward a circular economy. Red mud is an alkaline waste. It is difficult to dispose of and is often stored in dams. By converting it into high-purity silica, the company’s patented process addresses a waste problem. It also creates a new material source for a global industry.
The process:
Converting red mud to silicon wafers is a multi-step process.
First, scientists must purify the red mud, an industrial waste from aluminum production containing various metal oxides and silicon dioxide. This involves chemical leaching with acids or bases to selectively extract silicon. The resulting silicon-rich solution is then purified through multiple stages, such as filtration, to achieve the high purity required for semiconductors.
Finally, the purified silica is heated to over 1,500°C in an electric furnace with carbon to produce silicon. This silicon is further refined and grown into a single crystal to be sliced into wafers. Entity 1 Value Emissions Pvt. Ltd. has a patented process for this conversion.
Circular economy and global context:
The development directly ties into the principles of the circular economy, which aims to eliminate waste and keep resources in use. While other countries have explored using red mud for various applications like construction materials, wastewater treatment, and recovering valuable metals, no other nation has successfully converted it into semiconductor-grade silicon for wafer manufacturing. This gives India a unique first-mover advantage in the global semiconductor materials market.
The company’s technology is currently undergoing verification by Taiwan’s HIT in collaboration with major industry players like Taiwan Semiconductor Manufacturing Co. (TSMC) and Foxconn. This validation process is crucial for gaining credibility and ensuring that the red mud-derived wafers meet the stringent performance and quality standards of traditional silicon wafers. Ducon Infratechnologies states that its new wafers show performance on par with those made from prime silicon.
Strategic and financial impact:
The initiative aligns with India’s “Make in India” and broader decarbonization goals. A stable, domestic supply of wafers will strengthen India’s semiconductor supply chain, reduce reliance on imports, and mitigate risks from global supply disruptions. This localized production could also lower costs and ease price volatility for both domestic and international chipmakers.
Looking ahead, the company anticipates that this R&D initiative will create long-term value for investors. It offers the potential for high-margin services through engineering, procurement, and construction (EPC) opportunities for new plants. Furthermore, this sustainable approach could qualify the company for government incentives and subsidies, enhancing its financial outlook. Upcoming milestones include formal qualification programs with fabrication plants and initial customer revenue pilots.
According to Aron Govil, CMD, Ducon, “Solvent-based capture remains the most technically proven route for post-combustion applications, offering retrofit flexibility for brownfield facilities across India. By investing in solvent-based carbon capture R&D today, we aim to position Ducon as a trusted technology partner for customers seeking practical, bankable pathways to meet their CO₂ emissions targets.”
