Recovery of Rare Earth Elements from Coal and Coal Byproducts via a Closed Loop Leaching Process: Final Report (2017)

Objectives: Through this grant, Battelle proposes to address Area of Interest (AOI) 1 to develop a bench-scale technology to economically separate, extract, and concentrate mixed REEs from coal ash. U.S. coal and coal byproducts provide the opportunity for a domestic source of REEs. The DOE’s National Energy Technology Laboratory (NETL) has characterized various coal and coal byproducts samples and has found varying concentrations of REE ranging up to 1,000 parts per million by weight. The primary project objective is to validate the economic viability of recovering REEs from the coal byproduct coal ash using Battelle’s patented closed-loop Acid Digestion Process (ADP). This will be accomplished by selecting coal sources with the potential to provide REE concentrations above 300 parts per million by weight, collecting characterization data for coal ash samples generated via three different methods, and performing a Techno-Economic Analysis (TEA) for the proposed process. The regional availability of REE-laden coal ash, the regional market for rare earth concentrates, and the system capital and operating costs for rare earth recovery using the ADP technology will be accounted for in the TEA. Limited laboratory testing will be conducted to generate the parameters needed for the design of a bench scale system for REE recovery. The ultimate project outcome will be the design for an optimized, closed loop process to economically recovery REEs such that the process may be demonstrated at the bench scale in a Phase 2 project. Project Description: The project will encompass evaluation of the ADP technology for the economic recovery of REEs from coal and coal ash. The ADP was originally designed and demonstrated for the U.S. Army to facilitate demilitarization of cast-cured munitions via acid digestion in a closed-loop process. Proof of concept testing has been conducted on a sample of Ohio-based Middle Kittanning coal and has demonstrated the feasibility of recovering REEs using the ADP technology. In AOI 1, Ohio coal sources with the potential to provide a consistent source of rare earth element concentrations above 300 parts per million will be identified. Coal sample inventories from West Virginia and Pennsylvania will also be assessed for purposes of comparison. Three methods of preparing the coal ash will be evaluated for their potential to enhance the technical feasibility and economics of REE recovery. Three sources of coal ash are targeted for evaluation of the economics of REE recovery in this project: (1) coal ash from power generation stations, to include fly ash and/or bottom ash, (2) ash generated in a lower temperature ashing process, and (3) ash residual from Battelle’s coal liquefaction process. Making use of residual ash from coal liquefaction processes directly leverages work currently being conducted by Battelle for DOE NETL in response to DE-FOA-0000981 entitled “Greenhouse Gas Emissions Reductions Research and Development Leading to Cost-Competitive Coal-to-Liquids Based Jet Fuel Production.” Using the sample characterization results and regional information regarding REE concentration, availability and cost, a TEA will be developed. The previously generated laboratory testing results for leaching and REE recovery via the ADP will be used to perform the TEA, along with common engineering assumptions for scale up of equipment and labor costs. Finally, upon validation of the economic feasibility of the process by the TEA, limited laboratory testing will be performed to support the design of a bench scale system. In a future project phase, it is envisioned that the bench scale system will be constructed and operated to prove the process on a continuous basis.