Preferential Recovery of Rare-Earth Elements from Coal Fly Ash Using a Recyclable Ionic Liquid

Sustainable recovery of Rare Earth Elements (REEs) from coal and coal ash through urban mining: A Nature Based Solution (NBS) for circular economy

The demand for rare earth elements (REEs) has surged in recent years, driven by their crucial role in various industrial applications and their uneven geological distribution. As a result, urban mining from secondary resources, particularly coal and coal ash, has gained traction as a sustainable solution within a circular economy framework. This study highlights the significant presence of REEs in coal and coal ash, revealing that certain samples contain REE concentrations that rival traditional ores. Notably, coal ash has the potential to yield approximately 312,000 tons of REEs annually, far exceeding global demand. The research delves into advanced techniques for analyzing REEs, including elemental, isotopic, and mineralogical studies. Additionally, it explores innovative extraction methods such as the use of green solvents, nature-based solutions, and bioleaching and biosorption. By leveraging coal and its byproducts as secondary resources, this study underscores the opportunity to reduce dependence on conventional mining, enhancing the sustainability of REE recovery. A comprehensive literature review was conducted to highlight technological advancements and emerging opportunities that can address current challenges in this field.

Recovery of valuable elements from coal fly ash: A review

Coal fly ash is a solid waste produced during the combustion of coal in power plants, which occupies a vast area of land, entails high maintenance costs, and poses ecological and environmental risks. Nevertheless, coal fly ash contains abundant valuable elements, giving it potential utilization value. Considering the increasing depletion of native mineral resources worldwide and the restricted availability of rare earth elements, the recovery of valuable elements from coal fly ash is of great significance in addressing the issues of large-scale solid waste disposal and resource scarcity. This paper comprehensively summarizes the composition, content, distribution, and forms of various elements in coal fly ash, providing a scientific basis for subsequent recovery and utilization. It focuses on the methods and latest advancement in the recovery of valuable elements (such as Al, Si, Fe, Li, Ga and several rare earth elements) from coal fly ash, including physical beneficiation, hydrometallurgy, pyrometallurgy, and other novel processes. The effectiveness, benefits, and drawbacks of existing extraction methods are evaluated based on energy consumption, recovery efficiency, environmental consequences, and the future development direction of sustainable utilization of coal fly ash is discussed. The proposal of new technologies for the comprehensive, environmentally friendly, and low-energy consumption recovery of valuable elements from coal fly ash is aimed at promoting the comprehensive utilization of bulk solid waste and green economic development.

A review of greener approaches for rare earth elements recovery from mineral wastes

The use of rare earth elements (REE) in many various fields, including high-tech products, increases the demand for these materials day by day. The production of REE from primary sources has expanded in response to increasing demand; however, due to its limited, a more sustainable supply is also started to offer for the REE demand by using secondary sources. The most commonly used metallurgical method for REE recovery is hydrometallurgical processes. However, it has some disadvantages, like pyrometallurgical methods. In the review, studies of the environmental impacts of REE production from primary sources and life cycle assessments of products containing REE were investigated. According to the results, it has been seen that those studies in the literature in which hydrometallurgical methods have changed to more environmentally friendly approaches have begun to increase. In this review, mine wastes, which are secondary sources, were defined, conventional methods of recovery of rare earth elements were discussed, greener approaches to the recovery of REE from these sources were comprehensively examined and studies in the literature were evaluated. Furthermore, it was stated that there are limited studies on green approaches and REE recovery from mineral wastes and that this field is developing with an emphasis on the current outlook and future perspectives.

Recovery of rare earth elements from low-grade coal fly ash using a recyclable protein biosorbent

Rare earth elements (REEs), including those in the lanthanide series, are crucial components essential for clean energy transitions, but they originate from geographically limited regions. Exploiting new and diverse supply sources is vital to facilitating a clean energy future. Hence, we explored the recovery of REEs from coal fly ash (FA), a complex, low-grade industrial feedstock that is currently underutilized (leachate concentrations of REEs in FA are < 0.003 mol%). Herein, we demonstrated the thermo-responsive genetically encoded REE-selective elastin-like polypeptides (RELPs) as a recyclable bioengineered protein adsorbent for the selective retrieval of REEs from coal fly ash over multiple cycles. The results showed that RELPs could be efficiently separated using temperature cycling and reused with high stability, as they retained ∼95% of their initial REE binding capacity even after four cycles. Moreover, RELPs selectively recovered high-purity REEs from the simulated solution containing one representative REE in the range of 0.0001-0.005 mol%, resulting in up to a 100,000-fold increase in REE purity. This study offers a sustainable approach to diversifying REE supplies by recovering REEs from low-grade coal fly ash in industrial wastes and provides a scientific basis for the extraction of high-purity REEs for industrial purposes.

Engineering biomaterials for the recovery of rare earth elements

The escalating global demand for rare earth elements (REEs) and the overabundance of REE-containing waste require innovative technologies for REE recovery from waste to achieve a sustainable supply of REEs while reducing the environmental burden. Biosorption mediated by peptides or proteins has emerged as a promising approach for selective REE recovery. To date, multiple peptides and proteins with high REE-binding affinity and selectivity have been discovered, and various strategies are being exploited to engineer robust and reusable biosorptive materials for selective REE recovery. This review highlights recent advances in discovering and engineering peptides and proteins for REE recovery. Future research prospects and challenges are also discussed.

Rare Earth Element Adsorption to Clay Minerals: Mechanistic Insights and Implications for Recovery from Secondary Sources

The energy transition will have significant mineral demands and there is growing interest in recovering critical metals, including rare earth elements (REE), from secondary sources in aqueous and sedimentary environments. However, the role of clays in REE transport and deposition in these settings remains understudied. This work investigated REE adsorption to the clay minerals illite and kaolinite through pH adsorption experiments and extended X-ray absorption fine structure (EXAFS). Clay type, pH, and ionic strength (IS) affected adsorption, with decreased adsorption under acidic pH and elevated IS. Illite had a higher adsorption capacity than kaolinite; however, >95% adsorption was achieved at pH ∼7.5 regardless of IS or clay. These results were used to develop a surface complexation model with the derived binding constants used to predict REE speciation in the presence of competing sorbents. This demonstrated that clays become increasingly important as pH increases, and EXAFS modeling showed that REE can exist as both inner- and outer-sphere complexes. Together, this indicated that clays can be an important control on the transport and enrichment of REE in sedimentary systems. These findings can be applied to identify settings to target for resource extraction or to predict REE transport and fate as a contaminant.

Advances in bio/chemical approaches for sustainable recycling and recovery of rare earth elements from secondary resources

Rare Earth Elements (REEs) are indispensable in the growing smart technologies, such as smart phones and electronic devices, renewable energy, new generation of hybrid cars, etc. These elements are naturally occurring in specific geological deposits (bastnäsite, monazite, and xenotime), primarily concentrated in the regions of China, Australia, and the USA. The extraction and processing of REEs and the mismanagement of secondary REE resources, such as industrial waste, end-of-life materials, and mining by-products, raise major environmental and health concerns. Recycling represents a convincing solution, avoiding the necessity to separate low-value or coexisting radioactive elements when REEs are recovered from raw ore. Despite these advantages, only 1 % of REEs are usually recycled. This review overreached strategies for recycling REEs from secondary resources, emphasizing their pivotal role. The predominant approach for recycling REEs involves hydrometallurgical processing by leaching REEs from their origins using acidic solutions and then separating them from dissolved impurities using techniques like liquid-liquid extraction, membrane separation, chromatography, adsorption, flotation, and electrochemical methods. However, these methods have notable disadvantages, particularly their over requirements for water, reagents, and energy. Biohydrometallurgy introduces an innovative alternative using microorganisms and their metabolites to extract REEs through bioleaching. Other investigations are carried out to recover REEs through biological strategies, including biosorption, affinity chromatography with biological ligands, bioflotation employing biological surfactants, and bioelectrochemical methods. However, biohydrometallurgical processes can also be relatively slow and less suitable for large-scale applications, often lacking specificity for targeted REEs recovery. Overcoming these challenges necessitates ongoing research and development efforts to advance recycling technologies.

Rare Earth Elements Recovery and Waste Management of Municipal Solid Waste Incineration Ash

The advancements in high-tech products and pursuit of renewable energy demand a massive and continuously growing supply of rare earth elements (REE). However, REE production from mining is heavily restricted by technoeconomic limitations and global geopolitical tensions. Municipal solid waste incineration ash (MSWIA) has been recently recognized as a potential alternative for REE recovery. This study applies and optimizes a green modular treatment system using organic ligands for effective REE recovery and concentration from MSWIA with minimal generation of secondary wastes. Citrate extracted >80% of total REE at pH 2.0 and ∼60% at pH 4.0. A subsequent oxalate precipitation step selectively concentrated >98% of extracted REE by ∼7-12 times compared to raw MSWIA. Waste byproducts were upcycled to synthesize zeolites, resulting in an overall solid waste volume reduction of ∼80% and heavy metal immobilization efficiency of ∼75% with negligible leaching, bringing the dual benefits of REE recovery and waste management. This work serves as a pioneer study in REE recovery from an emerging source and provides system level insights on the practicality of a simple three-step treatment system. Compared to existing literature, this system features a low chemical/energy input and a light environmental footprint.

Separation and recovery of arsenic, germanium and tungsten from toxic coal ash from lignite by sequential vacuum distillation with disulphide

Large amount of coal ash is produced as industrial waste during the electricity generation through the combustion of lignite. Toxic elements arsenic exists in the coal ash, which hinders the subsequent recycling processes. Moreover, coal ash could be recycled further to retrieve scattered metals germanium and tungsten. It is believed that traditional recycling methods present barriers to scaled application, especially serious secondary pollution, such as toxic residue and waste liquid. In this work, a novel sequential vacuum distillation with disulphide method is proposed to separate arsenic, germanium and tungsten from coal ash. First, arsenic can be volatilized completely out of the reaction system at temperatures below 550 °C. Subsequently, Ge and W volatilized in the form of sulfide in the presence of Na2S2O3. The optimal condition was 1050 °C, the mass ratio of 0.6 with reaction a pressure of 1 Pa and a time duration of 120 min demonstrated the best evaporation ratio. For coal fly ash, chemical species As2S3, GeS, and WOx (x < 3)/WS2 were the main condensed products. For coal bottom ash, As2S3, GeS, and WO3/WS2 were dominant chemical components. Mechanisms for the process of release and evaporation of As, Ge, and W from coal ash, vacuum reaction, evaporation, and condensation were analyzed. In summary, the vacuum distillation method deserves to be further developed as it provides an eco-friendly method to recycle coal ash.

Controlling simonkolleite crystallisation via metallic Zn oxidation in a betaine hydrochloride solution

Zinc oxide nanoparticles, with a hexagonal flake structure, are of significant interest across a range of applications including photocatalysis and biomedicine. Simonkolleite (Zn₅(OH)₈Cl₂·H₂O), a layered double hydroxide, is a precursor for ZnO. Most simonkolleite synthesis routes require precise pH adjustment of Zn-containing salts in alkaline solution, and still produce some undesired morphologies along with the hexagonal one. Additionally, liquid-phase synthesis routes, based on conventional solvents, are environmentally burdensome. Herein aqueous ionic liquid, betaine hydrochloride (betaine·HCl), solutions are used to directly oxidise metallic Zn, producing pure simonkolleite nano/microcrystals (X-ray diffraction analysis, thermogravimetric analysis). Imaging (scanning electron microscopy) showed regular and uniform hexagonal simonkolleite flakes. Morphological control, as a function of reaction conditions (betaine·HCl concentration, reaction time, and reaction temperature), was achieved. Different growth mechanisms were observed as a function of the concentration of betaine·HCl solution, both traditional classical growth of individual crystals and non-traditional growth patterns; the latter included examples of Ostwald ripening and oriented attachment. After calcination, simonkolleite's transformation into ZnO retains its hexagonal skeleton; this produces a nano/micro-ZnO with a relatively uniform shape and size through a convenient reaction route.

Green Approach for Rare Earth Element (REE) Recovery from Coal Fly Ash

Due to the growing demands of rare earth elements (REEs) and the vulnerability of REEs to potential supply disruption, there have been increasing interests in recovering REEs from waste streams such as coal fly ash (CFA). Meanwhile, CFA as a large industrial waste stream in the United States (U.S.) poses significant environmental and economic burdens. Recovery of REEs from CFA is a promising solution to the REE scarcity issue and also brings opportunities for CFA management. This study demonstrates a green system for REE recovery from Class F and C CFA that consists of three modules: REE leaching using citrate, REE separation and concentration using oxalate, and zeolite synthesis using secondary wastes from Modules I and II. In Module I, ∼10 and 60% REEs were leached from the Class F and C CFA samples, respectively, using citrate at pH 4. In Module II, the addition of oxalate selectively precipitated and concentrated REEs from the leachate via the formation of weddellite (CaC₂O₄·2H₂O), while other trace metals remained in solution. In Module III, zeolite was synthesized using wastes from Modules I and II. This study is characterized by the successful recovery of REEs and upcycling of secondary wastes, which addresses both REE recovery and CFA management challenges.

Lanmodulin-Functionalized Magnetic Nanoparticles as a Highly Selective Biosorbent for Recovery of Rare Earth Elements

Recovering rare earth elements (REEs) from waste streams represents a sustainable approach to diversify REE supply while alleviating the environmental burden. However, it remains a critical challenge to selectively separate and concentrate REEs from low-grade waste streams. In this study, we developed a new type of biosorbent by immobilizing Lanmodulin-SpyCatcher (LanM-Spycatcher) on the surface of SpyTag-functionalized magnetic nanoparticles (MNPs) for selective separation and recovery of REEs from waste streams. The biosorbent, referred to as MNP-LanM, had an adsorption activity of 6.01 ± 0.11 μmol-terbium/g-sorbent and fast adsorption kinetics. The adsorbed REEs could be desorbed with >90% efficiency. The MNP-LanM selectively adsorbed REEs in the presence of a broad range of non-REEs. The protein storage stability of the MNP-LanM increased by two-fold compared to free LanM-SpyCatcher. The MNP-LanM could be efficiently separated using a magnet and reused with high stability as it retained ∼95% of the initial activity after eight adsorption-desorption cycles. Furthermore, the MNP-LanM selectively adsorbed and concentrated REEs from the leachate of coal fly ash and geothermal brine, resulting in 967-fold increase of REE purity. This study provides a scientific basis for developing innovative biosorptive materials for selective and efficient separation and recovery of REEs from low-grade feedstocks.

Highly-efficient and sequential recovery of rare earth elements, alumina and silica from coal fly ash via a novel recyclable ZnO sinter method

A novel sinter method using ZnO as the activator instead of the conventional Na₂CO₃/CaCO₃, (NH₄)₂SO₄, and K₂S₂O₇ was developed to achieve efficient sequential extraction of rare earth elements (REEs), alumina (Al), and silica (Si) from coal fly ash (CFA). Up to 93.3% Si, 87.1% REEs (70.7% Ce, 82.5% La, 83.2% Gd, 87.1% Nd, 62.3% Dy, and 81.7% Y), and 92.9% Al were extracted from CFA, respectively. Moreover, 93.1% of the ZnO activator was efficiently recycled, and the yield of red mud was only 14.9%. X-ray diffraction (XRD) and X-ray absorption near edge structure (XANES) results showed that the speciation transformation of Al/Si during CFA/ZnO roasting was as follows: mullite, quartz, amorphous Al₂O₃, and SiO₂ → Zn_0.75Al_1.5Si_1.5O₆, kyanite and willemite → gahnite and quartz/cristobalite solid solutions. The change in the REEs occurrence mode hinted at the migration of most REEs in aluminosilicates forms with Si during roasting, and disassociation with Si into the acid-soluble form after alkali leaching. These results indicate that the coupling of Al-Si-REE in CF was broken by this ZnO sinter method, promoting the sequential and efficient extraction of REEs, Al, and Si from CFA. This study provides a green and efficient strategy for element recovery from CFA, substantially reducing residues and favoring REEs concentration.

Environmental damage caused by coal combustion residue disposal: A critical review of risk assessment methodologies

Coal combustion generates almost 40% of world's electricity. However, it also produces 1.1 billion tons of coal combustion residues (CCR) annually, half of which end up in landfills. Although current regulations require proper lining and monitoring programs, the ubiquitous old, abandoned landfills are often not lined nor included in these programs. In addition, the total number of coal ash disposal sites and their status in the world is unknown. Therefore, this article reviews the environmental damage caused by CCR and three commonly used risk assessment methodologies: leaching assessment, groundwater assessment, and toxicity testing. Leaching methods are usually the first step in coal ash risk assessment, however, a large number of methods with different parameters make a comparison of data difficult. Groundwater pollution is commonly detected near coal ash disposal sites, but other anthropogenic activities may also exist nearby. Therefore, multivariate statistical methods and isotope traces should be used to differentiate between different sources of pollution. So far, both stable (δ¹⁸O, δD, δ¹¹B, δ³⁴S, δ⁷Li) and radiogenic (⁸⁷Sr/⁸⁶Sr, ²⁰⁶Pb/²⁰⁷Pb) isotopes have been successfully used as coal ash pollution tracers. Coal ash also negatively affects biota, reduces the diversity of organisms, affects children's health, and increases the risk for developing various diseases. Toxicity studies are great for early screening of coal ash safety; however, they provide no insights into mechanisms causing the adverse effects. Future directions are also proposed, such as the development of new 'low-level' detection methods for coal ash pollution and sustainable and selective method for recovery of critical elements.

Optimization of Iron Removal in the Recovery of Rare-Earth Elements from Coal Fly Ash Using a Recyclable Ionic Liquid

Rare-earth elements (REEs) are essential for modern technologies, and the United States currently lacks a secure domestic supply. Coal combustion residuals, specifically coal fly ash (CFA), can be a potential source. Our previous work demonstrated that REEs could be preferentially extracted from CFA using the ionic liquid (IL) betainium bis(trifluoromethylsulfonyl)imide ([Hbet][Tf₂N]), and the process yielded a mildly acidic REE-rich solution with coextracted Fe and regenerated IL. In this study, we investigated three strategies to limit Fe coextraction: magnetic separation, complexing salts, and ascorbic acid (AA) reduction. Magnetic separation of CFA was ineffective in significantly lowering the Fe content in the IL phase. When NaCl was used instead of NaNO₃ during extraction, chloride complexation lowered iron distribution to the IL phase over the aqueous phase (D_Fe) by five folds, from ∼75 to ∼14, while REE leaching (L_REEs) and recovery (R_REEs) both increased. Using AA for iron reduction lowered the overall amount of Fe extracted and further decreased D_Fe to ∼0.16, effectively shifting Fe preference from the IL phase to the aqueous phase. Combining the strategies of NaCl, AA, and supplemental betaine addition, leaching and extraction of REEs from CFA by [Hbet][Tf₂N] were achieved in higher efficiency for REE recovery with minimized Fe concentration.

A holistic approach for the recovery of rare earth elements and scandium from secondary sources under a circular economy framework - A review

Limited natural resources and a continuous increase in the demand for modern technological products, is creating a demand and supply gap for rare earth elements (REEs) and Sc. There is therefore a need to adopt the sustainable approach of the circular economy system (CE). In this review, we defined six steps required to close the loop and recover REEs, using a holistic approach. Recent statistics on REEs and Sc demand and the number of waste generations are reported and studies on more environmentally friendly, economic, and/or efficient recovery processes are summarized. Pilot-scale recovery facilities are described for several types of secondary sources. Finally, we identify obstacles to closing the REE loop in a circular economy and the reasons why secondary sources are not preferred over primary sources. Briefly, recovery from secondary sources should be environmentally and economically friendly and of an acceptable standard concerning final product quality. However, current technologies for recovery from for secondary sources are limiting and technology needs will vary depending on the source type. The quality/purity of the recovered metals should be proven so that they do not result in any adverse effects on the product quality, when they are being used as secondary raw material. In addition, for industrial-scale facilities, process improvements are required that consider environmental conditions.