A Low-cost Rare Earth Elements Recovery Technology
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1 Physical Sciences Inc. VG A Low-cost Rare Earth Elements Recovery Technology Prakash B. Joshi Andover, MA Presented at: World of Coal Ash Conference 2013 Lexington, KY 22 April New England Business Center Andover, MA 01810
2 Purpose VG Describe rationale for economical recovery of Rare Earth Elements (REE) using fly ash from U.S. coalfired power plants
3 Rare Earth Elements Nomenclature VG Group 3 Elements: Scandium, Yttrium, and lanthanides Classified into light, medium, and heavy Sc 21 La 57 Ce 58 Pr 59 Nd 60 Rare Earth Elements (REE) Pm 61 Sm 62 Eu 63 Gd 64 Tb 65 Dy 66 Ho 67 Er 68 Tm 69 Yb 70 Y 39 Lu 71 Light REE LREE Med. REE MREE Heavy REE HREE K-5899 Similarities to actinide series; PUREX-like extraction
4 Defense Applications of Rare Earth Elements Rare Earth Elements in Guidance and Control Systems VG Rare Earth Elements in Electric Motors Rare Earth Elements and Communication Source: Rare Earth Elements in National Defense: Background, Oversight Issues, and Options for Congress, V. Grasso, Congressional Research Service, 5 September 2012.
5 REE Applications in Clean Energy Technologies VG Electric Vehicles (Nickel Metal Hydride Batteries) Wind Turbines & Disk Drives (Permanent Magnets) La 2 O 3 Nd 2 O 3, Pr 6 O 11, Tb 2 O 7, Dy 2 O 3 Catalytic Converters CeO 2 Compact fluorescent lights (CFL) Y 2 O 3, Eu 2 O 3,Tb 2 O 7 Flat panel displays Eu 2 O 3,Tb 2 O 7, CeO 2 Magnetic Resonance Imaging Machines Gd Compounds
6 Criticality of Rare Earth Elements to Clean Energy VG Criticality = Importance to Clean Energy Tech X Risk of Supply Disruption HREE Tb, Dy, Y; MREE Gd, Eu; and LREE La, Ce, Nd critical/near critical
7 Rare Earths Are Really Not that Rare Relative abundance of rare earths >> precious metals Crustal concentration (220 ppm) is higher than that of carbon (200 ppm) VG Widely distributed in the earth s crust with some highly enriched concentration in certain minerals Common rare earth minerals: Bastnaesite (La, Ce, Y), Monazite (Th, La, Ce), Xenotime (Dy, Er, Tb, Yb), Ion adsorption clays (Y, Gd, Dy) Bastnaesite is considered most desirable due to high LREE concentrations with relatively low thorium content
8 Lanthanum (La) Cerium (Ce) Praseodymium (Pr) Neodymium (Nd) Samarium (Sm) Europium (Eu) Gadolinium (Gd) Terbium (Tb) Dysprosium (Dy) Holmium (Ho) Erbium (Er) Thulium (Tm) Ytterbium (Yb) Lutetium(Lu) Yttrium(Y) U.S. Mineral Resources Scarce in Heavy REEs LIGHT MEDIUM HEAVY VG LOCATION TYPE (S) Currently active: Bastnäsite Xenotime Ion adsorption clays Bayan Obo, Inner Mongolia Lahat, Perak, Malaysia Longnan, Jiangxi Province, China Possible Possibly to online come inonline the next in the 5 years: next 5 years: Bastnäsite Monazite Fergusonite Mountain Pass, California, United States Mount Weld, Australia Eastern coast, Brazil Nechalaco, Canada Wt% data: U.S. DoE Critical Material Strategy Reports Dec. 20l0/11 K-6411a
9 Coal Ash: A Resource with Substantial REE Content VG Russian and US literature: ~ 1 wt% (10,000 ppm) in Russian Far East coal ash* Rich in HREE Fly ash: An abundant waste product from coal-fired power plants in U.S. (~ 100M t annually) * Seredin, V. V., Rare earth element-bearing coals from the Russian Far East Deposits, Int. J. Coal Geology, 30, pp (1996).
10 Coal Combustion Enriches REE Content in Ash by ~ X10 Example of Russian Far East Coal (Black Stone Deposit) 1000 ppm LREE HREE TREE A 6000 ppm B LREE HREE TREE VG Coal Density Fraction (a) Before Combustion LREE, HREE Conc. ~ 0.25 wt% LREE/HREE ~ 1 Coal Density Fraction (b) After Combustion K-6445a * Seredin, V. V., Rare earth element-bearing coals from the Russian Far East Deposits, Int. J. Coal Geology, 30, pp (1996).
11 U.S. Coal Deposits with Total REE Content > 500 ppm and HREE/LREE Ratio > 10% VG U.S. coals from PA, WV, KY, AL and ND meet threshold
12 Fire Clay Coal Deposits in Eastern Kentucky: High Total REE Content in Ash VG LREE MREE HREE Location (County) Hyden East, (Leslie) Tilford, (Letcher) Tilford, (Letcher) Hazard South, (Perry) La Ce Pr Nd Sm Eu Gd Tb Dy H o Er T m Yb Y Y+RE E LRE E HREE LREE/ HREE TREE > 0.2 wt%, HREE/LREE > 20%
13 Comparative Evaluation of High-REE Content Coal Ash Relative to Traditional REE-rich Mineral Resources Coal ashes are better critical REE deposits than minerals: Coal Ash: Clusters II and III including eastern KY Fire Clay coal deposits Minerals: Cluster I Mountain Pass (US), Bayan Obo (PRC), and Mount Weld (Australia) Outlook Coefficient: * C outl = ((Nd+Eu+Tb+Dy+Er+Y)/ΣREY)/ (Ce+Ho+Tm+Yb+Lu)/ΣREY) Ky Fire Clay Coal I Norra Karr II Huashan Mount Weld Mountain Pass Bayan Obo III Kutessay II Longnan VG REE-rich coal ashes 2 Carbonatite deposits 3 Hydrothermal deposits 4 Weathered crust elution deposited (Ion-adsorbed) deposits * Seredin, V. V., Dai, S., Coal deposits as potential alternative sources for lanthanides and yttrium, International Journal of Coal Geology, 94, (2012) C outl K-8910a
14 Advantages of Coal Ash Over Minerals for REE Extraction I VG High costs and relative scarcity of REE are due to high costs of separation, concentration, and extraction from ores A very large fraction of the cost (~ 60%) is incurred in excavation, pulverization, and grinding of the minerals to a fine powder necessary for chemical processing Starting with good REE abundance in coal, the combustion of coal further concentrates the non-volatile REEs into fly ash by ~ 10X Fly ash is already available as fine powder (~ 100 micron scale), readily processable by chemical means, avoiding the mine-to-mill expenditures associated with mining
15 Advantages of Coal Ash Over Minerals for REE Extraction II Coal ash use as REE resource will significantly reduce energy use and accompanying CO 2 emission relative to conventional mining by ~ 75% VG PSI s REE extraction process will remove metals, including the hazardous elements arsenic, cadmium, and thorium from the coal ash, rendering it non-hazardous A value-added co-product of commercial importance used in cement and construction materials Beneficiation of coal ash Preprocessing prior to chemical extraction will also separate valuable commercial byproducts
16 10% 15% of Available Fly Ash Estimated to Meet U.S. REE Demand by 2020 REE content of ash ~ 1/40 th compared to minerals VG Estimate accounts for process yield and REE content variability
17 Developments Needed: Technological and Economic Feasibility Evaluation PSI has shown feasibility of efficient REE recovery from coal ash on laboratory scale Company funded project Seeking to further develop and scale up process Increase overall REE extraction efficiency Identify ash with high total REE content (>1000 ppm) and high HREE/LREE ratio (>10%) Enrich REE content via preprocessing Separation of REE and other elements separation Identify utility of byproducts and co-products Environmentally beneficiated ash Other elements of value Model process economics, energy use and environmental impact VG
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