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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Coupled Hydrothermal Extraction and Ligand-Associated Swellable Glass Media Recovery of Rare Earth Elements from Coal Fly Ash (Final Report)

Wayne State University (WSU) researchers, in collaboration with the University of California-Los Angeles (UCLA) and Los Alamos National Laboratory (LANL), have successfully developed a new sorbent media used in a process that concentrated the rare earth content in a coal fly ash sample from southeast MI by >350×, resulting in >13 wt% REO powder. The project developed a new DTPA-associated media that was used to concentrate total REEs. This project demonstrated a coupled hydrothermal extraction and solid-liquid recovery process that produced REO powder from raw fly ash while nearly eliminating the use of organic solvents. The project successfully: 1) identified a commercially viable ash supply with >$2.5 M in REO value being deposited monthly, 2) hydrothermally extracted >77% of REEs in coal fly ash (20% more than acid alone), 3) developed a new sorbent media that was used to concentrate REEs, 4) and engineered a process that resulted in a >13 wt% REO powder. The media also demonstrates a selectivity for mid and heavy REEs over Ce and La and the potential for use in separating individual rare earth elements. An invention disclosure for the sorbent media has been filed with WSU and a patent application will be submitted in the near future. The project examined the potential to couple hydrothermal leaching of coal fly ash with the engineering of a custom ligand-associated media to provide an organic solvent-free method of extracting and recovering REEs. Fly ash feedstock was collected from Detroit area coal-fired power plants, characterized for REE content, and subjected to a bench-top batch hydrothermal leaching/dissolution process inside custom-build pressure reactors at Los Alamos National Laboratory (LANL). This process applied a dissolution technique previously developed to process spent nuclear fuel and other nuclear materials. The modified ash was acidified and the resulting leachate was enriched with REEs along with Ca, Al, and Si. Ligands known to be effective in lanthanide/actinide separation were evaluated based on a series of criteria such as selectivity and association to organosilica through hydrophobicity. Batch experiments were conducted to establish the best conditions (e.g., pH, eluent, etc.) and best ligand systems for the effective extraction of REEs from the alkaline feed solution obtained from the hydrothermal leaching process. Once the organosilica-ligand extraction media was developed for REE concentration, an acidic solution was used to back extract and concentrate the REEs into a heavily REE-laden strip solution. The REEs in the strip solution were precipitated with oxalate to produce rare earth oxides.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Insights into coordination and ligand trends of lanthanide complexes from the Cambridge Structural Database

Abstract Understanding lanthanide coordination chemistry can help develop new ligands for more efficient separation of lanthanides for critical materials needs. The Cambridge Structural Database (CSD) contains tens of thousands of single crystal structures of lanthanide complexes that can serve as a training ground for both fundamental chemical insights and future machine learning and generative artificial intelligence models. This work aims to understand the currently available structures of lanthanide complexes in CSD by analyzing the coordination shell, donor types, and ligand types, from the perspective of rare-earth element (REE) separations. We obtain four sets of lanthanide complexes from CSD: Subset 1, all Ln-containing complexes (49472 structures); Subset 2, mononuclear Ln complexes (27858 structures); Subset 3, mononuclear Ln complexes without cyclopentadienyl ligands (Cp) (26156 structures); Subset 4, Ln complexes with at least one 1,10-phenanthroline (phen) or its derivative as a coordinating ligand (2226 structures). The subsequent analysis of lanthanide complexes in these subsets examines the trends in coordination numbers and first shell distances as well as identifies and characterizes the ligands and donor groups. In addition, examples of Ln-complexes with commercially available complexants and phen-based ligands are interrogated in detail. This systematic investigation lays the groundwork for future data-driven ligand designs for REE separations based on the structural insights into the lanthanide coordination chemistry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Selective recovery of rare earth elements with ligand-functionalized polymers in fixed-bed adsorption columns

Rare earth elements (REE) are a group of valuable metals with growing demand and broad applications. Mineral ores, the traditional sources of REE, require significant capital investment and their refinement has been a source of environmental contamination. Industrial fluids and natural REE-bearing liquids are potential alternative sources for these metals. This work investigated the performance and REE selectivity of polymer resin beads functionalized with N,N-bis(phosponomethyl)glycine (BPG) for extraction of REE from saline solutions in fixed-bed adsorption columns. Competitive batch adsorption experiments were conducted with various metals (Nd, Gd, Ho, Al, Fe, Co, Ni, Ba, Pb, Th, and U) and the BPG-functionalized resins were up to 137 times more selective for REE than aminated resins. In column experiments, the BPG-functionalized resins preferentially adsorbed heavier metals and REE were strongly retained in the functionalized column, taking 270 times longer than the amine column to reach 10% breakthrough and 128 times longer to reach 50% breakthrough. REE bound to the BPG-functionalized resins were recovered with a dilute HNO3 solution, yielding REE concentrations up to 236 times higher than the influent feedstock. This work provides new insight into the operational performance of novel functionalized adsorbents for recovery of REE from saline fluids.

42 ENGINEERING↗
DOE OSTI2026

Rare earth ion transport and selectivity in large diameter nanotube porins

Selective separation of rare earth elements (REEs) in nanoporous media is very challenging due to the similar physicochemical properties of trivalent lanthanide ions. In this work, we systematically investigate the transport and selectivity of REE 3+ ions through two model nanofluidic channels: 1.5 nm diameter carbon nanotube porins (wCNTPs) and 2.1 nm diameter boron nitride nanotube porins (BNNTPs). Using a fluorescence-based vesicle assay, we find that while wCNTPs show almost no differential selectivity across the lanthanide series, a behavior consistent with bulk-dominant transport through their moderately-confined channels with chemically inert, hydrophobic walls. In contrast, BNNTPs exhibit nearly an order of magnitude higher permeability and significant differential selectivity, following a volcano-shaped trend with Eu 3+ ions showing the highest permeability. We attribute this enhanced performance to the high negative surface charge of BNNTPs, which facilitates a surface-dominated transport mechanism where ion migration within the electric double layer becomes the primary contributor to conductance. These results elucidate the distinct roles of surface charge in nanoscale confinement and provide critical design rules for the development of future membranes tailored for efficient REE separations.

Materials science↗
DOE OSTI2025

Probing lanmodulin's mechanisms of rare-earth selectivity for protein-based bioseparations

Our BES Separation Science program project, DE-SC0021007, supported our efforts to begin to understand the mechanisms underlying selectivity of a novel class of lanthanide-binding proteins discovered by our laboratory, called lanmodulin (LanM), and to leverage these proteins for recovery and separations of trivalent rare earth elements (REEs) as well as of trivalent actinides. Overall, our work provides important insights into how higher-order (e.g., secondary, tertiary, and quaternary) protein structure modulates selectivity profiles of proteins that bind f-elements highly selectively. These results are important for advancing the concept of protein-based separations of REEs and, perhaps, of other critical minerals.

Lanmodulin, rare earth elements, protein-based met↗
DOE OSTI2022

The solution structures and relative stability constants of lanthanide–EDTA complexes predicted from computation

Ligand selectivity to specific lanthanide (Ln) ions is key to the separation of rare earth elements from each other. Ligand selectivity can be quantified with relative stability constants (measured experimentally) or relative binding energies (calculated computationally). The relative stability constants of EDTA (ethylenediaminetetraacetic acid) with La 3+ , Eu 3+ , Gd 3+ , and Lu 3+ were predicted from relative binding energies, which were quantified using electronic structure calculations with relativistic effects and based on the molecular structures of Ln–EDTA complexes in solution from density functional theory molecular dynamics simulations. The protonation state of an EDTA amine group was varied to study pH ~7 and ~11 conditions. Further, simulations at 25 °C and 90 °C were performed to elucidate how structures of Ln–EDTA complexes varying with temperature are related to complex stabilities at different pH conditions. Relative stability trends are predicted from computation for varying Ln 3+ ions (La, Eu, Gd, Lu) with a single ligand (EDTA at pH ~11), as well as for a single Ln 3+ ion (La) with varying ligands (EDTA at pH ~7 and ~11). Changing the protonation state of an EDTA amine site significantly changes the solution structure of the Ln–EDTA complex resulting in a reduction of the complex stability. As a result, increased Ln–ligand complex stability is correlated to reduced structural variations in solution upon an increase in temperature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Separation of Lanthanide Isotopes from Mixed Fission Product Samples

The measurement of radioactive fission products from nuclear events has important implications for nuclear data production, environmental monitoring, and nuclear forensics. In a previous paper, the authors reported the optimization of an intra-group lanthanide separation using LN extraction resin from Eichrom Technologies®, Inc. and a nitric acid gradient. In this work, the method was demonstrated for the separation and quantification of multiple short-lived fission product lanthanide isotopes from a fission product sample produced from the thermal irradiation of highly enriched uranium. The separations were performed in parallel in quadruplicate with reproducible results and high decontamination factors for 153 Sm, 156 Eu, and 161 Tb. Based on the results obtained here, the fission yields for 144 Ce, 153 Sm, 156 Eu, and 161 Tb are consistent with published fission yields. This work demonstrates the effectiveness of the separations for the intended application of short-lived lanthanide fission product analysis requiring high decontamination factors.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2022

Production of graphene-structured products from coal using thermal molten salt process

The invention provides a method for the production of graphene-structured products. The method generally comprises contacting at a conversion temperature ranging from about 850° C. to about 1100° C. in an inert atmosphere coal with a molten salt to produce a graphene-structured product. In an alternate embodiment, the method comprises contacting at a conversion temperature ranging from about 850° C. to about 1100° C. in an inert atmosphere coal with a molten salt to produce a graphene-structured product; and, separating a rare earth element from the graphene-structured product.

Shi, Fan↗
DOE OSTI2025

CMI Winter Meeting 2025 Presentation

Lanthanides are important to many technologies including magnets used in high efficiency traction motors. While common in the environment and industrial waste streams, lanthanides are often present at very low concentrations. This work demonstrates synergistic lanthanide recovery from an aqueous magnet leachate to single ppm concentrations using Na2SO4 addition and subsequent DME-FC treatment. It was found that combining DME-FC with low concentrations of Na2SO4 (~0.1 M) results in synergistic isolation of lanthanides while making use of Na2SO4, an excessive byproduct of hydrometallurgical metal production. Combined Na2SO4 + DME reduced lanthanide metal ion's (Pr, Nd, Sm, Gd, Dy, and Ho) solubilities by 1,000 - 25,000x with final concentrations ranging from 2 ppm to 200 ppm. This can be compared to 0.1 M Na2SO4 alone providing a 10 - 200x reduction and DME providing a 100 - 1,500x reduction in lanthanide solubilities. Final solution concentrations of lanthanides were 99.8% lower than what could not be achieved with either individual process. The results also reveal different periodic trends in the solubility reduction for DME and Na2SO4.

37 - INORGANIC, ORGANIC, PHYSICAL AND ANALYTICAL C↗
DOE OSTI2020

Continuous-Flow Centrifugal Solid/Liquid Separation for the Recovery of Rare-Earth Elements Containing Particles from Phosphoric Acid Sludge

Phosphoric acid sludge contains acid (~54% P 2 O 5 ) and solid precipitates including rare earth elements (REEs) at concentrations of ~2200 ppm. Low-cost recovery of valuable P 2 O 5 and simultaneous solid separation could be an economically feasible approach to recovering REEs while increasing the production of phosphoric acid. The sludge, however, is a complicated stream that cannot be separated by traditional technologies because of high viscosity and a large solid content (30–40%). Guided by a force balance model, an efficient solid/liquid separation method is demonstrated, using a continuous-flow centrifugal contactor. Additionally, the shear regime is bypassed by introducing the sludge directly into the rotor where a centrifugal force is exerted on the fluid, inducing phase separation. Solid particles are trapped in the contactor. High liquid recovery is demonstrated and the effects of process parameters on solid capture are investigated. Three contactors in series yield 94% recovery of solids containing 1500–2895 ppm of REEs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Enhanced rare-earth separation with a metal-sensitive lanmodulin dimer

Technologically critical rare-earth elements are notoriously difficult to separate, owing to their subtle differences in ionic radius and coordination number. The natural lanthanide-binding protein lanmodulin (LanM) is a sustainable alternative to conventional solvent-extraction-based separation. Here we characterize a new LanM, from Hansschlegelia quercus (Hans-LanM), with an oligomeric state sensitive to rare-earth ionic radius, the lanthanum(III)-induced dimer being >100-fold tighter than the dysprosium(III)-induced dimer. X-ray crystal structures illustrate how picometre-scale differences in radius between lanthanum(III) and dysprosium(III) are propagated to Hans-LanM’s quaternary structure through a carboxylate shift that rearranges a second-sphere hydrogen-bonding network. Comparison to the prototypal LanM from Methylorubrum extorquens reveals distinct metal coordination strategies, rationalizing Hans-LanM’s greater selectivity within the rare-earth elements. Finally, structure-guided mutagenesis of a key residue at the Hans-LanM dimer interface modulates dimerization in solution and enables single-stage, column-based separation of a neodymium(III)/dysprosium(III) mixture to >98% individual element purities. This work showcases the natural diversity of selective lanthanide recognition motifs, and it reveals rare-earth-sensitive dimerization as a biological principle by which to tune the performance of biomolecule-based separation processes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Extraction, Separation, and Production of High Purity Rare Earth Elements and Critical Minerals from Coal-Based and Related Resources

The general objectives of this project are to develop concepts for rare earth metal and critical mineral production from coal-based and related (minerals associated with coal) resources and incorporate them into a Technical Research Plan with an associated overall flow sheet. The project team has extensive expertise in market evaluation, mineral separation, leaching, chemical separations, alternative metallothermic reaction technology, electrowinning, and electrorefining that was critical to the success of the proposed project. The project included critical industrial partners needed for project success. The project team has extensive expertise in market evaluation, mineral separation, leaching, chemical separations, alternative reduction technology, electrowinning, and electrorefining as well as appropriate pilot-scale facilities to enable this project. The project encompassed broader opportunities for developing domestic resources of REE/CM materials for a more resilient, diverse, and secure supply chain for REE/CM materials with built-in redundancies and appropriate resource stockpiles. The production of REE/CM materials will help to revitalize and rebuild world-class American manufacturing capacity and the related workforce through new jobs and infrastructure. Furthermore, due to the nature and location of the production sites, economic growth in diverse communities of color and economically distressed areas will be cultivated. Finally, this technology can be applied to reuse and remediate coal waste tailings for REE/CM production.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Chemically Enhanced Electrodialysis (CEED) for Recovery of Rare Earth Elements

Rare-earth elements are crucial for numerous technologically relevant industries including energy, electronics, and aerospace; however, both the supply and separation of rare earths are pressing challenges. The long-term goal of the collaborative project is to develop a novel approach to existing extraction behaviors. To achieve this goal, a class of electrodialysis membranes with novel ion-gating functionality will be developed and paired with a conventional electrodialysis strategy. The hypothesis of the work is that incorporating sequestrants of suitable structures at the surface of the electrodialysis membrane will enhance extraction efficiency for ions of interest. Our ability to prepare sequestrants of diverse conformations and to adapt their molecular structure for binding lanthanides renders the proposed technology a versatile method for selective ion separation. Our approach will enable an entirely new technological approach to the separation of valuable rare-earth elements.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Pilot-Scale Testing of an Integrated Circuit for the Extraction of Rare Earth Minerals and Elements from Coal and Coal Byproducts Using Advanced Separation Technologies

The primary objective of this project was to develop and demonstrate an integrated pilot-scale circuitry for recovering high-value rare earth elements (REEs) from coal and coal byproducts. The target performance was to produce a mixed REE product with content of at least two percent by weight on a dry mass basis in a cost-effective and environmentally benign manner. During the first nine months of the project period (Phase 2 Budget Period 2), pilot plant construction was completed including all field site startup activities such as permitting, engineering design, procurement/bidding, unit fabrication, site construction, equipment installation, module assembly, safety training, and circuit shakedown. During the remaining 21 months of project period (Phase 2 Budget Period 3), detailed field-testing activities were performed including feedstock sample collection and preparation, exploratory testing, circuit modification, detailed parametric study, and performance optimization. A detailed techno-economic analysis was performed based on the pilot plant testing findings which provided various scenarios for REE production. The project successfully accomplished the proposed target performance by producing mixed rare earth oxide (REO) with greater than 90% purity by weight in a continuous pilot scale operation from two distinctly different coarse refuse materials (i.e., West Kentucky No. 13 and Fire Clay coal seams), and at least three secondary sources (i.e., heap leach process and naturally formed acid mine drainage system). Project partners included the University of Kentucky, Virginia Tech, West Virginia University, Alliance Coal, Blackhawk Mining, Mineral Refining Company, and Mineral Separation Technologies. The pilot scale test facility was constructed at a former mining complex owned by Alliance Natural Resource Partners (Alliance Coal). The site was rehabilitated to accommodate the equipment installation, construction and fabrication, electrical power requirement, water line management and containment. The process units constructed and installed included X-ray sorting unit, crushing and grinding unit, physical separation unit, acid leaching unit, solvent extraction unit, and wastewater management unit. A rare earth mineral concentration unit was constructed as a standalone unit for flexible operation. A detailed environmental assessment and control plan was carried out to identify and quantify any potential impacts of the pilot-scale processing circuitry on the human and eco-system health and well-being. Corresponding mitigation strategies and control measures were provided. A conceptual flowsheet was developed to effectively remove thorium and uranium from high purity rare earth oxide mix or any potential radionuclide enriched stream. The two distinct feedstock materials were secured from the Blackhawk Mining Complex in eastern Kentucky where the Fire Clay (Hazard No. 4) seam is processed. The West Kentucky No. 13 (Baker) coarse refuse material was collected from an active process stream at an Alliance coal preparation plant located in western Kentucky. Characterization analysis indicated that both of feed materials generated from the two sources contained >300 ppm of TREEs on a dry whole mass basis which met the requirements for a qualified feed stock. The two feedstocks were further upgraded using a dual x-ray sorter to prepare the feed material for hydrometallurgical circuit. Thermal treatment on feed material prior to leaching was found to: 1) improve the leaching recovery of REEs, 2) increase the leaching kinetics, and 3) allow the leaching reaction to occur at lower acidity. Roasting at 600°C was selected as the pre-treatment condition for both West Kentucky No. 13 and Fire Clay coarse refuse material. Over 40% of leaching recovery was achieved by roasting West Kentucky No. 13 material having a top particle size of 3 mm in the pilot scale operation using 1.2M sulfuric acid leaching at 75OC. Initial pilot scale testing involved continuous operation of the pilot plant for 94 hours. The leaching unit was operated at solid-to-liquid ratio of 1 to 10 (w/v) using 0.5M sulfuric acid solution at a temperature of 75°C. The continuous solvent extraction circuit utilized rougher and cleaner units with DEHPA and TBP as the extractants. An innovative stripping circuit was developed to accumulate the REE concentration in the stripping solution to a level above 600 ppm. A bleed stream from the recycled strip solution was treated using oxalic acid precipitation which produced a high grade rare earth oxalate. The oxalate product was roasted to remove the oxalate which produced a rare earth oxide product having a purity greater 90%. Due to high concentrations of contaminant ions in the pregnant leach solution (PLS), a modified flowsheet was developed that involved pre-concentration of the REEs using multiple stages of precipitation and redissolution. The advantage of this process was improved removal of contamination before the downstream purification process and a significant cost reduction relative to the circuit that utilized the solvent extraction process. The modified circuitry included processes involving leaching, multistage precipitation, redissolution, and oxalate precipitation followed by roasting of the oxalate product. The circuit produced a mixed REO that was 92.96% pure from the initial test. A detailed parametric test plan was carried out which involved varying key parameters including solids feed rate, acid flowrate, acid concentration, multistage precipitation pH, redissolution pH, oxalate precipitation dosage and pH. The response variables included REE recovery, contaminant recovery, REO product grade and overall chemical consumption. Test results indicated that the acid-to-solid ratio is the key parameter to leaching efficiency as performance deteriorated with an increase in solids concentration. The optimal pH determined for REE precipitation and redissolution was 6.5 and 2.5, respectively. Additional tests were conducted to further improve the flowsheet. Recirculating a portion of the PLS to the feed of the leach tanks improved the leaching performance by lowering the pH of the leaching system and reducing the contamination recovery by shortening the residence time. Moreover, the removal of Al prior to REE precipitation significantly reduced the oxalic acid consumption in the oxalate precipitation circuit. The modified circuit produced over 90% grade REO by weight from both West Kentucky No. 13 and Fire Clay coarse refuse material in pilot scale continuous test programs. A case analysis model was developed to project the REE and major contaminants concentration in each PLS stream based on the leaching condition, pH cut point, and oxalic acid dosage. A correlation was established using empirical and semi-empirical models. Using the models, chemical consumption required for each stage was predicted based on the projected performance of the hydrometallurgy circuit. After identifying the optimum conditions, validation tests were carried out for the treatment of both West Kentucky No. 13 and Fire Clay coarse refuse materials in the pilot plant. The actual circuit performance and chemical consumptions were very close to the model predictions. Other than the two coarse refuse sources, several secondary feedstocks were also tested in the pilot plant facility. A “heap leach” system was constructed using the coarse refuse material generated from cleaning the West Kentucky No. 13 seam coal. Using the two stage SX rougher and cleaner circuit, a concentrate with a grade >90% REO was produced while recovering >97% of the REEs from the heap leach PLS. Naturally generated acid mine drainage (AMD) from West Kentucky No.13 mine was processed using the multistage precipitation circuit in the pilot plant in a test conducted for a period of 32 hours. The final grade of the mix RE oxide produced from the AMD was 90.84% with an overall circuit recovery of 64%. The primary source of REE was the selective precipitation steps involving iron and aluminum rejection. The hydrophobic-hydrophilic separation (HHS) process was proven to effectively recover coal from fine waste materials. For REM recovery, the HHS process was able to produce concentrates at grades of approximately 1.8% REE on an ash basis; however, recovery values were typically low, <10%, under the optimal conditions determined in the laboratory-scale testing. Staged testing of the pilot-scale HHS process for coal recovery and semi-continuous laboratory testing for REM testing showed that a total concentration ratio of more than 15x was observed for the REM recovery process. A circuit simulation package was developed for REE extraction and purification using a spreadsheet-based platform (Microsoft Excel). The REESim circuit simulation package is configured to track the mass and volume flows of components passing through a series of unit operations specified and configured by the user. The mass rates can then be utilized by the user to determine important performance indicators such as product mass yields, concentrate purity levels, element-by-element recoveries, and so forth. The techno-economic analysis showed that the roasting and leaching operations were the most expensive capital items, each contributing approximately 30% to the total capital cost. One notable contributor to the high production costs was the low REE recovery observed in the pilot scale trials. The product basket price was shown to have a strong influence on the economic viability of the scenarios, with the scandium price being the most significant influencer. Operating cost was shown to be extremely sensitive to REE recovery, REE feed grade, and leaching acid consumption. An analysis of ten different scenarios for a 500 t/h commercial operation revealed that three were economically favorable, producing internal rates of return varying from 27.7% to 33.1% and payback periods of 4 to 5 years. The project successfully developed and demonstrated a process to recover REEs from coal and coal byproducts in a pilot-plant operation which consistently produced over 90% grade REO mix from varies types of feedstocks. Commercialization analysis showed that the technology readiness level successfully achieved TRL 6 at the end of the project and demonstrated the need and the potential for scaling the process to further advance the technologies toward the goal of providing a domestic supply of REEs at a commercial scale.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Reactive Grinding of Coal Ash For Enhanced Rare Earth Extraction

Monazite and coal ash contain varying trace amounts of Rare Earth Elements (REE). Rare earth elements are considered to be the elements in the lanthanide series. These elements be categorized into two separate groups, light and heavy rare earth groups. Rare Earth Elements play an essential role to society and industry and can be found in a spectrum of applications such as Capacitors, Power Generation, and Catalysts for Petroleum Refining. Due to the abundance of Coal Ash and ongoing production, there is an increasing interest from the scientific community to develop renewable source of energy by extracting rare earth elements from within its contents. Commercial and experimental reactive grinding and leaching procedures have been created to help to maximize the recovery of Rare Earth Elements from Coal Ash.

Keller, Murphy↗
DOE OSTI2024

Exploring the Structural Behavior of Hydrophilic Diglycolamide Complexes with the Lanthanides and Actinides

In the ongoing effort to meet the anticipated rise in energy demand while maintaining the full-scale abandonment of natural gas and coal, a substantial shift in our considerations of green energy is required through the wider adoption of nuclear power. However, the advantages of nuclear power are hindered by the challenges of safely managing nuclear waste. Hydrophilic diglycolamides (DGA) ligands have been explored for use as stripping agents in various lanthanide and actinide partitioning processes. Additionally, the separation of lanthanide fission products and transplutonic actinides can serve multifaceted advantages in that the separation neutron poisoning rare earth element (REE) fission products from minor actinides from used nuclear fuel (UNF) can be mutually beneficial to the fundamental research behind REE separations and UNF separations. With this in mind, understanding the bonding differences between the Ln3+ and An3+ ions as a function of DGA structure, such as varying the alkyl groups on each of the amide functional groups, has an influence on the molecule’s selectivity and solubility and whose changes in molecular architecture also impact the radiolytic behavior of these molecules. As such, crystal structures of (Y3+, La-Lu3+, excl. Pm, Pu3+/4+, Am3+, Bk3+, and Cf3+) with hydrophilic diglycolamides show the systematic progression, and changes in coordination habits, as a function of a f-element ions. These coordination complexes see a consistent decrease in bond lengths and changes in the coordination environment while traversing across the f-elements, owing to the effects of the lanthanide contraction as well as local geometry around the metal centers. Direct comparisons of lanthanide with actinide DGA structures display both striking similarities in coordination with earlier actinides of Pu and Am, while later actinides of Bk and Cf display a complete breakdown of these observed trends. This work has also presented the rare opportunity to study homoleptic DGA compounds across multiple oxidation states have provided insight into their nuanced differences in structural chemistry.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2023

Multi-Sourced Collaboration for the Production and Refining of Rare Elements and Critical Metals (Final Technical Report)

The project objective was to develop a feasible and cost-effective method for recovering rare earth elements (REEs) and critical materials (CMs) from coal and coal byproducts, resulting in high-purity individually separated REEs and CMs. The targeted REEs included Y, Pr, Nd, Gd, Dy, and Sm, with a purity of over 99.5%, while the CMs included Co, Mn, Ga, Sr, Li, Ni, Zn, and Ge, with a purity of over 90%. The project aimed to design a prototype facility capable of producing 1-3 tonnes/day of high-purity REO mixes. The work was divided into four designated circuits: 1) REE extraction and concentration, 2) REE separation and purification, 3) RE metal production, and 4) CM production. To achieve these goals, the project involved 11 tasks, including technology reviews, research, process flow diagram development, mass balance estimation, and preliminary technical-economic analysis. The project team included researchers from the University of Kentucky, University of Alabama and Virginia Tech as well as process specialists from Argonne National Laboratory. MP Materials provided technical support regarding rare earth markets and processing while Alliance Coal performed resource assessment. The project included a market analysis for Nd/Pr, Tb, Dy, Gd, Y, Co, Mn, Li, Sr, Ga, Ni, Zn, and Ge. These analyses provided insights into the supply and demand trends as well as historic and future projections of market price relative to purity requirements for these elements. Two coal resources were selected for the project: the West Kentucky No. 13 (Baker) Seam and an undisclosed lignite resource in the Illinois coal basin. The estimated quantities of REEs in these resources were calculated based on production samples and drilling data. It was estimated that there is adequate supply for an operation producing one metric ton daily of higher purity mixed rare earth oxides (MREO) for approximately 20 years at a site located in western Kentucky. In Circuit 1, project data was obtained from a pilot heap leach and REE concentration facility. It was concluded that the existing circuit, which generated a MREO concentrate, two types of CM mixed products, and Li- and Sr-containing waters, would be suitable feed for circuits 2-4. Data from the first-of-its-kind coal coarse refuse heap leach pilot pad played a crucial role in estimating reliable elemental concentrations of the pregnant leaching solution (PLS). The average total REE concentration in the PLS was found to be 28.6 ppm. In Circuit 2, several concepts were explored including a novel process referred to as solvent-assisted chromatography (SAC). This concept involved a novel columnar reactor that incorporated multiple mixer/settlers, thereby enabling the operation of counter-flowing aqueous and organic phases. Unfortunately, due to project time constraints, a complete fundamental modeling analysis could not be completed to fully evaluate the technology. Molten salt electrowinning was considered as an alternative for circuit 3 following circuit 2 purification circuit utilizing the novel SAC process. A mass and energy balance of Nd reduction to metal in a fluoride containing molten salt electrolyte was conducted. Comparisons were made with the current state of Asian molten salt electrorefining, and potential improvements in siphoning rare earth metals (REM) from the reactor were presented. A cost estimate was performed for the production of 1 tonne per day, which yielded a total of $2.29 million for the nine electrowinning (EW) cells required. The selected option for circuits 2 and 3 was a plasma distillation process, which initially separates rare earth elements (REEs) from other elements. This is followed by selective electrowinning in various ionic liquids. The selection was made on the basis of thermodynamic modeling and experimental data previously published by a project partner. The combination offers an innovative approach to integrated refining and RE metal production. For Circuit 4, an extensive literature review was conducted for the processing of the CMs. The ultimate decision was to utilize a combined plasma and ionic liquid process as well to produce individual high-purity concentrates of Zn, Ni, Co, Mn, and Mg. A separate flowsheet for Li and Sr was recommended, which would yield carbonates of these elements. Due to the lack of suitable experimental data at this time, a process recommendation could not be provided but several methods have been proposed for consideration. Lastly, a techno-economic analysis (TEA) was conducted to assess the effectiveness of the proposed process for further investigation. The TEA results revealed a capital expense (CapEx) of $737 million and an annual operational expense (OpEx) of $220 million. Due to the selected elements, the hypothetical heap leach pad can produce 1 metric tonne per day of REO equivalent, but a conscious decision was made to only treat targeted REEs, resulting in the production of 0.4 metric tonne of REM. An estimated annual revenue of $90.87 million was projected based on standard market pricing information provided by the funding agency. During the TEA, ten different modules were evaluated for costing purposes. The precipitation circuit was identified as the largest single operational expense, followed by the Mg/Mn process due to the amount of treated metal. In terms of capital expenditures, the heap leach process incurred the highest cost, followed by the Mg/Mn process. The scalability of the plasma process is a crucial consideration since the reactors cannot be scaled beyond the largest demonstrated size due to their reliance on surface area of the slag and vapor phase. The purity estimate for the REEs are generally 98%±2% to produce a metal. The purity level being lower than the project objective was due to the lack of specific experimental data needed to tighten the tolerance of the estimates. Based on literature and previous experience, the CMs are estimated as follows; Ga (95%+, metal), Sr (95%+, carbonate), Li (95%+, carbonate), Ni (98%±2%, metal), Zn (95%+, metal sponge), Ge (95%+, metal), Co (98%±2%, metal), and Mn (98%±2%, metal).

01 COAL, LIGNITE, AND PEAT↗