The Application of Current Mineral Processing and Extractive Metallurgy Technologies to Potential Rare Earth Ores in the U.S. Coal Measures: Near-Term Opportunities to Fill Out the U.S. Value Chain
This report will consider the potential for currently available mineral processing and extractive metallurgy technologies to produce separated rare earth compounds from U.S. coal and coal byproducts. Implementation of production as such would require restoration of elements of the rare earth value chain that have recently been absent in the U.S., notably for chemical extraction of rare earth compounds from the mineral form (i.e. hydrometallurgical extraction). A variety of existing technologies are available for use in both mineral processing and extractive metallurgy applied to RE production in the U.S. As will be discussed, once a mineral concentrate is produced, the contained rare earth value can be large compared with transportation costs, and the sections of the value chain dealing with chemical extraction (the largest cost) and separation into individual rare earth compounds can be remotely located. Also, as will be discussed, this has been the rule rather than exception in the history of the rare earth industry in the U.S. A strategy, possibly to include repurposing of existing metallurgical processing facilities, will be presented for near-term production, using a decentralized set of facilities. Also presented will be research results from the Office of Fossil Energy (FE) and the National Energy Technology Laboratory (NETL), within the U.S. Department of Energy, relevant to economic feasibility of rare earth production, notably from the standpoint of establishing which materials are capable of providing economic production. Simple methodologies are presented for both establishment of cutoff grades and economic evaluation of a process. The goal of this report is to present an overview of methods and pathways that will result in “the achievement of near-term rare earth production, using currently available technologies to produce a mixed, chemical extracted rare earth concentrate, and existing and new facilities to produce separated rare earths that can “plug in” to the metals and magnet production facilities.” A set of recommendations appears at the end of this work, involving both research and project development activities which will enable the achievement of this noble goal. A set of recommendations appears at the end of this work, involving both research and project development activities.