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Powder River Basin CORE-CM: Advancing Strategies for Carbon Ore, Rare Earth Element, and Critical Mineral Resource Development in the Nation's Largest Coal Producing Basin
A parametric study using geochemical modeling to optimize the CO2 mineralization potential of mafic ore bodies
In the present study, a unique method is adopted to achieve higher reducibility of titaniferous magnetite lump ore (TMO). In this method, TMO is initially heated followed by water quenching. The quenching process generates cracks due to thermal shock in the dense TMO lumps, which, in turn, increases the extent of reduction (EOR) using the lean grade coal as a reductant. The optimum combination of parameters found by using Taguchi’s L{sub 27} orthogonal array (OA) (five factors, three levels) is − 8 + 4 mm of particle size (PS{sub 1}), 1423 K of quenching temperature (Qtemp{sub 2}), 15 minutes of quenching time (Qtime{sub 3}), 3 times the number of quenching {(No. of Q)_3}, and 120 minutes of reduction time (Rtime{sub 3}) at fixed reduction temperature of 1473 K. At optimized levels of the parameters, 92.39 pct reduction is achieved. Isothermal reduction kinetics of the quenched TMO lumps at the optimized condition reveals mixed controlled mechanisms [initially contracting geometry (CG3) followed by diffusion (D3)]. Activation energies calculated are 69.895 KJ/mole for CG3 and 39.084 KJ/mole for D3.
To explore the feasibility of small-scale sintering pot testing, a ‘millipot’ facility (diameter of 53 mm and height of 400 mm) was established and used to examine the sintering performance of iron ores and other non-traditional ferrous materials. The sintering performance of a millipot was examined across a range of different operational conditions (coke rate and suction pressure) and compared with an industrial sinter strand operation. Tablet tests were also performed to assist in the design of the millipot experiments and identify conditions for achieving mineral composition similar to the industrial sinter. For the millipot experiments, the materials used need to be compacted to increase the bulk density, and a higher coke rate is required to compensate the high heat loss caused by wall effects. A higher suction pressure is also necessary to maintain an oxidizing atmosphere in the sinter bed. As expected, it was not possible to eliminate the wall effect, which resulted in more primary hematite at edges of the sintered column. However, the sintered material from the center of column simulates industrial sinter reasonably well. As such, millipot provides a practical way to evaluate the sintering process and material performance at laboratory scale, helping to bridge the gap between tablet sintering and large scale pot sintering, or full scale plant trial. The results of millipot testing can be used for designing larger scale experiments or commercial sintering trials.
The reduction kinetics of hematite iron ore fines to metallic iron by hydrogen using a laboratory fluidized bed reactor were investigated in a temperature range between 873 K and 1073 K, by measuring the weight change of the sample portion during reduction. The fluidization conditions were checked regarding plausibility within the Grace diagram and the measured pressure drop across the material during experiments. The apparent activation energy of the reduction was determined against the degree of reduction and varied along an estimated two-peak curve between 11 and 55 kJ mol{sup −1}. Conventional kinetic analysis for the reduction of FeO to metallic iron, using typical models to describe gas–solid reactions, does not show results with high accuracy. Multistep kinetic analysis, using the Johnson–Mehl–Avrami model, shows that the initial stage of reduction from Fe{sub 2}O{sub 3} to Fe{sub 3}O{sub 4}, and partly to FeO, is controlled by diffusion and chemical reaction, depending on the temperature. Further reduction can be described by a combination of nucleation and chemical reaction, whereby the influence of nucleation increases with an increasing reduction temperature. The results of the kinetical analysis were linked to the shape of the curve from apparent activation energy against the degree of reduction.
Although magmatic- and metamorphic- derived fluids are widely recognized mineralizing agents, the role of crustal architecture in defining source and sink zones within the middle to lower crust and upper mantle of ancient orogens remains enigmatic. The globally largest and best-preserved Archean greenstone belts lie in the Superior Province, Canada. They provide an ideal location to investigate the influence of igneous construction and subsequent syn-deformational plutonism and metamorphism on the localization of metal-rich melts and fluids throughout the crustal column. Integration of three-dimensional magnetotelluric modelling and seismic reflection sections across the Abitibi subprovince reveals details of a 'whole-of-crust' magmatic and hydrothermal system. East-west low resistivity structures broadly underlie the surface traces of the major deformation zones that are host to significant gold endowment (>200 Moz), while mid-crustal cross trends suggest mineralized fluids flowed along 'pipes' within fault planes. Most low resistivity structures are inferred to represent domains containing interconnected zones of graphite and/or sulfide. Furthermore, these delineate relict mantle source/transit domains and crustal pathways enriched by the flow of magmas or metamorphic fluids genetically related to a late-stage pulse of ore-bearing magmatism, possibly as a result of slab break-off or delamination. Using the combined MT and seismic data, we develop a 3-D crustal-scale model which highlights how evolving orogenic architecture-controlled mass transfer and metallogenic processes developed.
Presented here is a look at different inductively coupled plasma (ICP) platforms including sector field, triple quadrupole mass spectrometric configurations, and optical emission spectroscopy. The goal of this paper was to convey the feasibility of trace elemental analysis of a uranium ore concentrate with varying ICP-based platforms. It was predicted that low mass elements would be better determined through optical means, or the mass collision/reaction technology of the triple quadrupole mass spectrometer, in comparison to high resolution measurements of magnetic sector-based configurations. Ultimately, it is difficult to achieve an “optimal” analysis of 20+ elements, for numerous samples, on a single platform, especially when time, measurement reproducibility, sensitivity, and robustness should be considered. The work presented here highlights the advantages and disadvantages of the respective trace elemental analysis platforms.
Efficient separation of rare earth element (REE) ores via froth flotation requires the development of novel ligands with enhanced adsorption capacity and selectivity. To realize these advances, understanding the mechanisms underlying interactions between the ligand and mineral surfaces is essential. This study systematically evaluates the adsorption behavior of alkyl- and aromatic alkyl-substituted hydroxamic acid ligands on monazite surfaces using complementary spectroscopic techniques, including UV–visible (UV–vis) spectroscopy, Raman spectroscopy, infrared spectroscopy, and vibrational sum frequency generation (SFG) spectroscopy, together with the ab initio molecular dynamics (AIMD) simulations. Among the studied ligands, octanohydroxamic acid (OHA) and 4-ethoxy-N,2-dihydroxybenzamide (EDHBA) exhibit high adsorption capacity under basic pH (8–10) by forming multilayers on the surface. OHA has a higher equilibrium adsorption capacity compared to EDHBA, but it forms a less stable multilayer susceptible to disruption in the presence of interfering ions. AIMD results show that OHA adopts a single stable chelating geometry, while EDHBA exhibits multiple binding modes involving distinct interactions with La surface atoms and phosphate-bound oxygens, resulting in more complex adsorption kinetics. The variations in surface binding and intermolecular interactions observed between alkyl and aromatic molecules influence the differences in adsorption kinetics, equilibrium adsorption capacities on the mineral surface, and their flotation performance. This work provides valuable insight into the adsorption mechanism of ligands at mineral interfaces, which is crucial for guiding the design of new ligands with enhanced separation performance.
Here, in this study, data from thirteen laboratories from around the world are presented for a successful certification of uranium isotope ratios in uranium ore concentrate (UOC) certified reference materials from the National Research Council Canada. Different mass spectrometric measurement principles (including SF-ICP-MS, quadruple ICP-MS, TIMS, MC-ICP-MS, SIMS and AMS) and measurement procedures were employed. In general, data from all sources exhibit good consistency with TIMS and MC-ICP-MS showing superior performance. The three candidate UOC CRMs (UCLO-1, UCHI-1 and UPER-1) have natural uranium isotope ratios with certified values of 0.5304(7) x 10 -4 , 0.5475(2) x 10 -4 and 0.5361(4) x 10 -4 for n( 234 U)/n( 238 U) and 0.007 2563(13), 0.007 2563(10) and 0.007 2542(11) for n( 235 U)/n( 238 U), respectively, with expanded uncertainty (k = 2) applicable to the last digit of the value given in the parentheses. Information values for n( 236 U)/n( 238 U) in these three CRMs, measured by AMS, are also provided: 10 x 10 -12 , 200 x 10 -12 and 22 x 10 -12 . The uncertainties of the proposed certified values of uranium isotope ratios in UOC CRMs are superior to available reference materials, and the values of n( 234 U)/n( 238 U) and n( 236 U)/n( 238 U) show significant variation among the three CRMs.
The blast furnace process is a counter-current moving bed chemical reactor to reduce iron oxides to iron, which involves complex transport phenomena and chemical reactions. The iron ore and coke are alternatively charged into the blast furnace, forming a layer by layer structural burden which is slowly descending in the counter-current direction of the ascending gas flow. We proposed a new methodology to efficiently simulate the gas and solid burden flow in the counter current moving bed in blast furnace shaft. The gas dynamics, burden movement, chemical reactions, heat and mass transfer between the gas phase and solid phase are included. Furthermore, the new methodology has been developed to explicitly consider the effects of the layer thickness thermally and chemically in the CFD model.
This report represents the twenty-seventh and Final Technical Progress Report issued in connection with the subsidence remediation projects undertaken by Rockaway Township in Morris County, New Jersey. This report provides a summary of the major project work accomplished during this last reporting period ending June 30, 2010 and a summary of the work accomplished since the agreement inception in 1997. This report is issued as part of the project reporting provisions set forth in the Cooperator's Agreement between the United States Government - Department of Energy, and Rockaway Township. The purpose of the Cooperator's Agreement is for the Department of Energy to provide technical and financial assistance in a coordinated effort with Rockaway Township to develop and implement a multi-phased plan to remediate ground stability problems associated with abandoned mining activity. Primarily during the 1800's, extensive iron ore mining and prospecting was undertaken in Rockaway Township, part of the Dover District Mining region in Morris County. The abandoned mining activity has resulted in public safety hazards associated with ground collapse and surface subsidence features evolving in both developed and undeveloped areas within Rockaway Township. At the Green Pond Mine site at the Township's Jacobs Road Compost Storage Facility, surface monitoring continued after completion of construction in September 2003. Surface monitoring was conducted periodically at the Mt. Hope Road subsidence work area and adjacent areas after the January 2000 construction effort. In March 2007, a seventh collapse occurred over a portion of the White Meadow Mine in a public roadway at the intersection of Iowa and Erie Avenues in Rockaway Township. After test drilling, this portion of the mine was remediated by drilling and grouting the stopes.
Fuel use and explosives emissions for mining rare earth containing ore for the Mountain Pass mine. To access the model referenced in the report, please visit https://www.netl.doe.gov/energy-analysis/details?id=3F54D9CC-AE2F-469C-8E72-5066B5EDF14E
This report summarizes early work on an advanced electrochemical process to produce low-cost titanium from domestic ore. While titanium is a versatile and robust structural metal, it's widespread adoption for consumer applications has been limited due to its high cost of production. Early feasibility evaluation for developing a new electrochemical titanium production process that avoids the cyclical formation of undesired titanium ions, thus significantly increasing the electrical current efficiency is investigated. This study begins what could significantly reduce the costs and energy consumption associated with producing titanium.
This report is intended to provide the background on domestic rare earth production and provide potential opportunities for the near-term restoration of the rare earth value chain in the U.S. Background and contextual material is provided on the domestic rare earth industry, as is an overview of the economics of processing rare earth ores through the value chain, including a deeper assessment of different mineral processing pathways and opportunities. This is followed by a discussion on knowledge gaps and key research areas that can address them in developing rare earth production in the near term.
The U.S. Department of Energy’s (DOE’s) Office of Fossil Energy awarded 13 Carbon Ore, Rare-Earth and Critical Minerals (CORE-CM) programs as part of the CORE-CM Initiative, designed to develop the technology and upstream and midstream supply chains to extract rare-earth elements (REEs) and CMs from the nation’s coal supplies. The intent is to catalyze regional economic growth and job creation while strengthening the use of domestic resources. The Williston Basin CORE-CM Program aims to drive the expansion and transformation of coal and coal-based resource usage within the Williston Basin to produce REEs, CMs, and nonfuel carbon-based products (CBPs). The work constitutes Phase 1 of a long-term program. The objectives of Phase 1 are to identify the existing knowledge base and gaps and to develop a series of assessments/plans, including an initial basinal assessment; a characterization and data acquisition plan; a waste stream reuse plan; a basinal strategies assessment for infrastructure, industries, and business; a technology assessment, development, and field-testing plan; a technology innovation center plan(s); and a stakeholder outreach and education plan. Originally, the CORE-CM programs were to do little if any sample collection as part of the Phase 1 program. As part of the ongoing interactions with DOE regarding the progress of the 13 CORE-CM programs, DOE has decided to extend Phase 1 with additional funding to allow all of the Phase 1 CORE-CM programs to collect and characterize more samples that have potential to be sources of REEs and CMs. The goal of this project is to initiate the development of a new industry in the resource-rich Williston Basin that will generate economic growth and job creation through a coalition team of private industry; university; and state, local, and federal government entities. A coalition team of nearly 30 private industry; university; and state, local, and federal government partners was formed for this program. Partners include the University of North Dakota Energy & Environmental Research Center, Institute for Energy Studies, and Nistler College; North Dakota State University; Montana Tech University; Pacific Northwest National Laboratory; Critical Materials Institute; North Dakota Geological Survey; South Dakota Geological Survey; U.S. Geological Survey; North American Coal Corporation; BNI Energy; Basin Electric Power Cooperative; Minnkota Power Cooperative; and many more.
Final Report; Illinois Basin - Carbon Ore, Rare Earth and Critical Mineral (IB-CORE-CM) project team has conducted a comprehensive basin-wide assessment of CORE-CM presence in coal, coal-based, and waste stream resources, as well as a thorough examination of mining practices, separation technologies, and the local infrastructure necessary for producing and providing the needed CORE-CM resources for U.S. industry. This final report details the research, methods, and results of the project.
The final report outlines the outcomes of the Alaska CORE-CM Program, funded by the U.S. Department of Energy under award DE-FE0032050. Led by the University of Alaska Fairbanks and the Alaska Division of Geological and Geophysical Surveys, with assistance from other organizations, the project assessed Alaska's potential for Carbon Ore, Rare Earth Elements, and Critical Minerals (CORE-CM). Leveraging advanced analytical techniques, the project identified high-potential resource basins, evaluated geochemical and satellite data, and conducted targeted field investigations. Findings revealed promising concentrations of critical minerals in legacy samples and newly collected materials. The project also investigated innovative extraction technologies, including BioExtraction and use of supercritical CO2, which show significant promise for sustainable resource recovery. Additionally, the study explored the reuse of waste streams from active mining operations and coal byproducts such as using alkali-activated coal ash to manufacture concrete. Infrastructure and logistical challenges in Alaska’s remote regions are discussed, alongside strategies to establish a Technology Innovation Center aimed at advancing CORE-CM development in Alaska. The report includes actionable insights to support Alaska’s critical role in securing domestic supplies of essential minerals while addressing economic, environmental, and technological challenges.
Presented at the 48th International Technical Conference on Clean Energy (Clearwater Clean Energy Conference), Clearwater, Florida, June 16-19, 2024. This presentation describes the Energy & Environmental Research Center’s development of the Upgraded Carbon Ores-to-Products (UCOP) technology to produce high‑quality graphite and other critical materials from coal and coal wastes for clean energy applications such as batteries and electrodes. It outlines the technical approach, including feedstock cleaning, controlled heat treatment, and graphitization, and presents results demonstrating high graphite purity, novel microstructures, and competitive performance relative to commercial graphite. The work highlights the potential for lower environmental impact and domestic supply chains for critical materials amid increasing global demand and supply‑chain constraints.