A Laboratory Study to Simulate Ore Sorting for a Rare Earth Ore
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Metallurgy & Metallurgical Engineering↗
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Evolution of ore deposits on terrestrial planets
Ore deposits on terrestrial planets materialized after core formation, mantle evolution, crustal development, interactions of surface rocks with the hydrosphere and atmosphere, and, where life exists on a planet, the involvement of biological activity. Core formation removed most of the siderophilic and chalcophilic elements, leaving mantles depleted in many of the strategic and noble metals relative to their chondritic abundances. Basaltic magma derived from partial melting of the mantle transported to the surface several metals contained in immiscible silicate and sulfide melts. Magmatic ore deposits were formed during cooling, fractional crystallization and density stratification from the basaltic melts. Such ore deposits found in earth's Archean rocks were probably generated during early histories of all terrestrial planets and may be the only types of igneous ores on Mars. Where plate tectonic activity was prevalent on a terrestrial planet, temporal evolution of ore deposits took place. Repetitive episodes of subduction modified the chemical compositions of the crust and upper mantles, leading to porphyry copper and molybdenum ores in calc-alkaline igneous rocks and granite-hosted tin and tungsten deposits. Such plate tectonic-induced mineralization in relatively young igneous rocks on earth may also have produced hydrothermal ore deposits on Venus in addition to the massive sulfide and cumulate chromite ores associated with Venusian mafic igneous rock. Sedimentary ore deposits resulting from mechanical and chemical weathering in reducing atmospheres in Archean earth included placer deposits (e.g., uraninite, gold, pyrite ores). Chromite, ilmenite, and other dense unreactive minerals could also be present on channel floors and in valley networks on Mars, while banded iron formations might underlie the Martian northern plains regions. As oxygen evolved in earth's atmosphere, so too did oxide ores. By analogy, gossans above sulfide ores probably occur on Mars, but not submarine ferromanganese nodules and crusts which have precipitated in oxygenated seawater on earth.
Burns, R. G.↗
A geochemical assessment of possible lunar ore formation
The Moon apparently formed without appreciable water or other relatively volatile materials. Interior concentrations of water or other volatile substances appear to be extremely low. On Earth, water is important to the genesis of nearly all types of ores. Thus, some have reasoned that only abundant elements would occur in ore concentrations. The definition and recognition of ores on the Moon challenge the imaginations and the terrestrial perceptions of ore bodies. Lunar ores included solar-wind soaked soils, which contain abundant but dilute H, C, N, and noble gases (including He-3). Oxygen must be mined; soils contain approximately 45 percent (wt). Mainstream processes of rock formation concentrated Si, Mg, Al, Fe, and Ca, and possibly Ti and Cr. The highland surface contains approximately 70 percent (wt) feldspar (mainly CaAl2Si2O8), which can be separated from some highland soils. Small fragments of dunite were collected; dunite may occur in walls and central peaks of some craters. Theoretical extensions of observations of lunar samples suggest that the Moon may have produced ores of trace elements. Some small fragments have trace-element concentrations 10(exp 4) times higher than the lunar average, indicating that effective geochemical separations occurred; processes included fractional crystallization, silicate immiscibility, vaporization and condensation, and sulfide metamorphism. Operations of these processes acting on indigenous materials and on meteoritic material in the regolith could have produced ores. Infalling carbonaceous meteorites and comets have added water and hydrocarbons that may have been cold-trapped. Vesicles in basalts, pyroclastic beads, and reported transient events suggest gag emission from the lunar interior; such gas might concentrate and transport rare elements. Large impacts may disperse ores or produce them through deposition of heat at depth and by vaporization and subsequent condensation. The main problem in assessing lunar resources is the ignorance about the largely unexplored Moon.
Haskin, Larry A.↗
Rhenium Isotope Reconnaissance of Uranium Ore Concentrates
Exploration of natural isotopic variations of the element rhenium (Re) is in its infancy, with initial studies revealing isotopic fractionation in a variety of geological materials. Here, in this work, we investigate Re isotope variation as a new geochemical tool, given its redox-sensitive properties and affinity for organic matter and sulfides. In this work, Re abundance and isotope ratio data were collected from uranium ore concentrates (UOCs) across a variety of depositional ages, locations, geologic settings, and deposit types. Ore types from which the UOC were derived include sandstone, unconformity, and quartz-pebble (QP) conglomerate. To isolate Re from the U-rich matrix of UOCs, a new purification method utilizing DGA ion exchange resin was developed. We found that UOCs exhibit a wide range of Re isotope ratios, with sandstone ore-derived UOCs having the isotopically lightest values, QP conglomerate ore-derived UOCs having the heaviest, and unconformity ore-derived UOCs in between (with some overlap with sandstone UOCs). The Re isotope ratio range observed in UOCs extends previously reported values by more than a factor of two. Industrial processing (e.g., incomplete recovery of Re from ore, contamination, fractionation during processing) may play a role in the isotopic variability in the UOCs. However, systematic differences between ore types suggest that the depositional setting is a significant factor. For nuclear forensic investigations, Re isotopic compositions combined with data from other isotopic systems provide geochemical signatures that can aid in provenance assessment of UOCs. Regardless of the specific causes for the wide range of Re isotope ratios in UOCs, these initial data indicate Re is a promising tool for nuclear forensic investigations on samples from early in the nuclear fuel cycle.
58 GEOSCIENCES↗
Elucidating key reducing species beyond ions in hydrogen plasma smelting reduction of iron ore
Hydrogen plasma smelting reduction (HPSR) of iron ore has attracted significant attention over the past decade due to its high-temperature operation, rapid plasma mediated reduction kinetics, and simpler density-based separation of molten iron product, compared to H2-based solid-state reduction. All of these attributes enable processing of low-grade ores for downstream use in electric-arc furnaces, as virgin iron with low gangue content is required for high quality steel and improved furnace operation. While positive ions exist within the plasma arc, this work demonstrates that near the anodic ore surface, hydrogen radicals and vibrationally excited hydrogen species dominate and their densities correlate well with observed reduction rates. Species concentrations in the transferred plasma arc and at the plasma-ore interface are evaluated using coupled thermal plasma and near-wall non-equilibrium plasma models. The thermal plasma model is validated against experimental voltage data and spectroscopic measurements of plasma temperature and density for varying current inputs. Modeling of the near surface thermochemical non-equilibrium and micrometer scale anode sheath layer reveals, in addition to the expected H + , significant concentrations of ArH + and H$^+_3$ ions, typically not observed in thermal plasmas under thermodynamic equilibrium. Our results show that the inverted sheath structure at the anodic ore surface strongly suppresses reactive positive ion fluxes, while non-equilibrium electron-impact processes generate abundant hydrogen radicals and vibrationally excited species. These findings highlight the critical role of non-equilibrium effects in hydrogen arc-driven iron ore reduction and advance understanding beyond prevailing hypotheses centered on hydrogen ion-driven mechanisms.
08 HYDROGEN↗
Electrochemical lithium extraction from hectorite ore
Electrochemical technologies add a unique dimension for ore refinement, representing tunable methods that can integrate with renewable energy sources and existing downstream process flows. However, the development of electrochemical extraction technologies has been impeded by the technological maturity of hydro- and pyro-metallurgy, as well as the electrical insulating properties of many metal oxide ores. The fabrication and use of carbon/insulating material composite electrodes has been a longstanding method to enable electrochemical activation. Here, using real hectorite ore, we employ this technical approach to fabricate hectorite-carbon black composite electrodes (HCCEs) and achieve electrochemical activation of hectorite. Anodic polarization results in lithium-ion release through a multi-step chemical and electrochemical mechanism that results in 50.7 ± 4.4% removal of lithium from HCCE, alongside other alkaline ions. This technical proof-of-concept study underscores that electrochemical activation of ores can facilitate lattice deterioration and ion removal from ores.
25 ENERGY STORAGE↗
High-Fidelity Arc-Discharge Model for Hydrogen-Plasma-Smelting-Reduction of Iron Ore
Electrification and use of renewable hydrogen is currently a necessity for decarbonizing the iron-and-steel industry. In this regard, hydrogen plasma smelting reduction (HPSR) is a novel pathway that is being explored for reduction of iron ore. HPSR provides several decarbonization merits compared to conventional blast furnaces. Firstly, the use of renewable hydrogen drastically reduces the CO2 emissions compared to the use of coke. Secondly, renewable electricity in the form of a thermal plasma for making reactive hydrogen species (radicals, ions) are more efficient at reducing iron ore compared to neutral H2. Thirdly, a molten product compatible with downstream processes is obtained from the intense heat transfer from the plasma. However, the scale-up of this technology requires fundamental exploration of hydrogen plasma dynamics and its interaction with complex solid material that include phase changing iron-ore and slag. In this work, we present a first principles continuum scale model for thermal plasmas in Ar/H2 gas mixtures typically used for HPSR. The thermal plasma governing equations for mass, momentum and energy with Lorentz force and Joule heating source terms are solved along with electromagnetic equations for electrostatic and magnetic vector potential. Our solver will be based on Pele, a suite of reacting flow solvers designed for advanced scientific computing architectures (Henry De Frahan et al., Proceedings of SIAM Parallel Processing, 13-25, 2024), and will utilize adaptive mesh generation for enhanced resolutions at locations of intense physicochemical interactions. This study will present the impact of Ar to H2 ratios on excited/dissociated hydrogen species concentrations, plasma temperature and conductivity along with the impact of outgassed species (water, metal vapor, O, OH radicals) from ore surface on gas phase chemistry. Furthermore, the heat and species flux to the surface will be quantified as a function of applied voltages in a transferred arc configuration.
hydrogen plasma↗
Hydrogen-based ore-to-part manufacturing of near-net-shape stainless steel
Decarbonizing iron and steelmaking, combined with global disruptions to raw material supply chains, necessitates novel approaches to iron and steel production. In this work, we demonstrate a direct ore-to-part manufacturing route using a mixture of ore-derived oxide powders of Fe 2 O 3 , Cr 2 O 3 , NiO, and MoO 3 as feedstock for additive manufacturing, combined with sintering under H 2 to produce a near-net-shape austenitic stainless-steel. Complete reduction of all constituent oxides, including MoO 3 and Cr 2 O 3 , is achieved in-situ at 1300 °C, resulting in dense, crack-free bulk alloy. The fabricated part retains geometric fidelity while undergoing substantial volumetric shrinkage inherent to redox and sintering. Thermodynamic calculations elucidate the co-reduction mechanisms and alloying pathways that enable complete metallization. This work is the first demonstration of net-shaping metal parts directly from ore derived oxides, and this ore-to-part approach can minimize the emissions and lead time for manufacturing associated with downstream processing such as rolling, forging, and machining.
Yang, Mingzhang [Univ. of Waterloo, ON (Canada); F↗
Development of Novel Sintered Carbon-Ore Building Materials
The main objective for this project was to develop value-added products from carbon-ore leading to commercialization of a carbon-based product. These carbon-based products (LIG2 products) are produced using the sintered carbon-ore building materials (SCBM) technology and have carbon contents greater than 70 wt.% carbon with greater than 51wt.% of the carbon coming from carbon-ore. The project team produced LIG2 bricks at a rate of five bricks per day and characterized the material properties of the bricks. These products can then be used in fabrication of a carbon-based building. A technical and economic analysis (TEA), cradle-to-grave life cycle analysis (LCA), technology gap analysis, and conceptual design were also completed for the LIG2 carbon-ore brick manufacturing process.
01 COAL, LIGNITE, AND PEAT↗
The formation of ore mineral deposits on the Moon: A feasibility study
Most of the ore deposits on Earth are the direct result of formation by hydrothermal solutions. Analogous mineral concentrations do not occur on the Moon, however, because of the absence of water. Stratified ore deposits form in layered instrusives on Earth due to fractional crystallization of magma and crystal settling of high-density minerals, particularly chromium in the mineral chromite. We have evaluated the possibility of such mineral deposition on the Moon, based upon considerations of 'particle settling velocities' in lunar vs. terrestrial magmas. A first approximation of Stoke's Law would seem to indicate that the lower lunar gravity (1/6 terrestrial) would result in slower crystal settling on the Moon. However, the viscosity of the silicate melt is the most important factor affecting the settling velocity. The viscosities of typical lunar basaltic melts are 10-100 times less than their terrestrial analogs. These lower viscosities result from two factors: (1) lunar basaltic melts are typically higher in FeO and lower in Al2O3, Na2O, and K2O than terrestrial melts; and (2) lunar igneous melts and phase equilibria tend to be 100-150 C higher than terrestrial, largely because of the general paucity of water and other volatile phases on the Moon. Therefore, particle settling velocities on the Moon are 5-10 times greater than those on Earth. It is highly probable that stratiform ore deposits similar to those on Earth exist on the Moon. The most likely ore minerals involved are chromite, ilmenite, and native FeNi metal. In addition, the greater settling velocities of periodotite in lunar magmas indicate that the buoyancy effects of the melt are less than on Earth. Consequently, the possibility is considerably less than on Earth of deep-seated volcanism transporting upper mantle/lower crustal xenoliths to the surface of the Moon, such as occurs in kimberlites on Earth.
Taylor, Lawrence A.↗
Production of Solar Cells in Space from Non Specific Ores by Utilization of Electronically Enhanced Sputtering
An ideal method of construction in space would utilize some form of the Universal Differentiator and Universal Constructor as described by Von Neumann (1). The Universal Differentiator is an idealized non ore specific extractive device which is capable of breaking any ore into its constituent elements, and the Universal Constructor can utilize these elements to build any device with controllability to the nanometer scale. During the Human Exploration Initiative program in the early 1990s a conceptual study was done (2) to understand whether such devices were feasible with near term technology for the utilization of space resources and energy. A candidate system was proposed which would utilize electronically enhanced sputtering as the differentiator. Highly ionized ions would be accelerated to a kinetic energy at which the interaction between them and the lattice elections in the ore would be at a maximum. Experiments have shown that the maximum disintegration of raw material occurs at an ion kinetic energy of about 5 MeV, regardless of the composition and structure of the raw material. Devices that could produce charged ion beams in this energy range in space were being tested in the early 1990s. At this energy, for example an ion in a beam of fluorine ions yields about 8 uranium ions from uranium fluoride, 1,400 hydrogen and oxygen atoms from ice, or 7,000 atoms from sulfur dioxide ice. The ions from the disintegrated ore would then be driven by an electrical field into a discriminator in the form of a mass spectrometer, where the magnetic field would divert the ions into collectors for future use or used directly in molecular beam construction techniques. The process would require 10-7 Torr vacuum which would be available in space or on the moon. If the process were used to make thin film silicon solar cells (ignoring any energy inefficiency for beam production), then energy break even for solar cells in space would occur after 14 days.
Curreri, Peter A.↗
Neutron capture signatures determined from gadolinium isotope compositions of uranium ore concentrates using MC-ICPMS
We present Gd isotope compositions on 25 well-characterized uranium ore concentrates (UOCs). About half the UOCs have isotope depletions in 157 Gd coupled with anticorrelated excesses in 158 Gd due to neutron capture effects. UOCs from older ore bodies and with higher U contents show larger neutron capture effects than UOCs from younger ore bodies with lower U contents. These Gd data are correlated with their previously measured Sm isotope compositions, and we use the Sm data to estimate the neutron fluence of these samples. In conclusion, this work demonstrates how Gd isotope signatures can be employed as a new tool for nuclear forensics.
Earth Sciences↗
Enhanced grindability of bastnaesite ore by ex-situ CO 2 treatment under the partial pressure of 0-100 psi
High grinding energy consumption has long constrained the sustainable development of mineral processing. This study introduces an innovative technology that employs ex-situ CO 2 treatment to enhance the grindability of bastnaesite ore. The grinding aid effect was evaluated under CO 2 partial pressures ranging from 0 psi to 100 psi using particle size distribution and the Bond work index (BWI), while the underlying mechanism was elucidated with various characterization techniques including inductively coupled plasma (ICP), scanning electron microscopy (SEM), thermogravimetric analysis (TGA), and Brunauer-Emmett-Teller (BET). The optimal grinding aid effect was achieved at 100 psi partial pressure, 50% slurry concentration, and 3 h reaction duration. Correspondingly, the P80 of the grinding product decreased from 81.76 μm to 72.73 μm and the BWI of bastnaesite ore decreased from 6.96 kW·h/t to 6.30 kW·h/t, a reduction of 9.48%. The grinding aid effect primarily resulted from the transformation of sparingly soluble carbonates like calcite and dolomite into more soluble bicarbonates, which created substantial cracks and pores, thereby reducing the ore's hardness and improving its grindability. By significantly saving grinding energy consumption while delivering environmental benefits, this technology exhibits great promise for further optimization and widespread adoption.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Application of LANDSAT satellite imagery for iron ore prospecting in the Western Desert of Egypt
Prospecting for iron ore occurrences was conducted by the Remote Sensing Center in Bahariya Oasis-El Faiyum area covering some 100,000 km squared in the Western Desert of Egypt. LANDSAT-1 satellite images were utilized as the main tool in the regional prospecting of the iron ores. The delineation of the geological units and geological structure through the interpretation of the images corroborated by field observations and structural analysis led to the discovery of new iron ore occurrences in the area of investigation.
Elshazly, E. M.↗
Application of LANDSAT satellite imagery for iron ore prospecting in the western desert of Egypt
The author has identified the following significant results. The delineation of the geological units and geological structures through image interpretation, corroborated by field observations and structural analysis, led to the discovery of new iron ore deposits. A new locality for iron ore deposition, namely Gebel Qalamun, was discovered, as well as new occurrences within the already known iron ore region of Bahariya Oasis.
Elshazly, E. M.↗
Ore deposits in Africa and their relation to the underlying mantle
African magmatism is largely related to the tensional stress regimes of the crust which are induced by the hotter upwelling mantle rocks. These mantle rocks may provide emanating forces and thermal energy for the upward movements of primary ore bodies with fluid inclusions in the tensional stress regimes of the crust. In this paper, the Goddard Earth Gravity Model is used to calculate a detailed subcrustal stress system exerted by mantle convection under Africa. The resulting system is found to be correlated with the African metallogenic provinces. Recognition of the full spectrum of ore deposits in Africa that may be associated with the hotter upwelling mantle rocks has provided an independent evidence to support the hypothesis of mantle-derived heat source for ore deposits.
Liu, H.-S.↗
The indirect electrochemical refining of lunar ores
Recent work performed on an electrolytic cell is reported which addresses the implicit limitations in various approaches to refining lunar ores. The cell uses an oxygen vacancy conducting stabilized zirconia solid electrolyte to effect separation between a molten salt catholyte compartment where alkali metals are deposited, and an oxygen-evolving anode of composition La(0.89)Sr(0.1)MnO3. The cell configuration is shown and discussed along with a polarization curve and a steady-state current-voltage curve. In a practical cell, cathodically deposited liquid lithium would be continuously removed from the electrolytic cell and used as a valuable reducing agent for ore refining under lunar conditions. Oxygen would be indirectly electrochemically extracted from lunar ores for breathing purposes.
Semkow, Krystyna W.↗
Possible lunar ores
Despite the conventional wisdom that there are no lunar ores, geochemical considerations suggest that local concentrations of useful rare elements exist on the Moon in spite of its extreme dryness. The Moon underwent protracted igneous activity in its history, and certain magmatic processes can concentrate incompatible elements even if anhydrous. Such processes include: (1) separation of a magma into immiscible liquid phases (depending on composition, these could be silicate-silicate, silicate-oxide, silicate-sulfide, or silicate-salt); (2) cumulate deposits in layered igneous intrusions; and (3) concentrations of rare, refractory, lithophile elements (e.g., Be, Li, Zr) in highly differentiated, silica-rich magmas, as in the lunar granites. Terrestrial mining experience indicates that the single most important characteristic of a potential ore is its concentration of the desire element. The utility of a planet as a resource base is that the welter of interacting processes over geologic time can concentrate rare element automatically. This advantage is squandered if adequate exploration for ores is not first carried out.
Gillett, Stephen L.↗