Development of Separation and Purification Methods for Producing Rare Earth Elements from Coal Fly Ash

Hoon Choi, Purdue University

Abstract

Rare earth elements (REEs) are critical materials in many electronics and green technology products. Though the demand for REEs is growing rapidly, China controls over 90% of the REEs supply and the US currently is not producing any REEs. As most of the REEs occurred together in the mineral ores with low concentrations and they have similar chemical and physical properties, the extraction and purification processes are challenging. Conventional methods for producing REEs require large amounts of toxic chemicals and generate large amounts of hazardous wastes. Therefore, it is important to develop alternative REE sources as well as efficient and environmentally friendly processes to produce REEs domestically. In this dissertation, coal fly ash, a major coal combustion byproduct, was explored as a potential source for REEs. Novel separation and purification methods were developed for producing high purity REEs from class F coal fly ash. First, a sequential separation process was developed to recover and concentrate REEs from class F coal fly ash. The ash was first digested using a NaOH solution and subsequently dissolved in an acid to extract REEs as well as other chemicals. About 74% of REEs, 92 % of SiO2, 74% of Al2O3, 24% of Fe2O3, and 65% of CaO were extracted. Most (>99%) of the extracted REEs and cations (Al+3, Fe+3, Ca+2) were captured in a cation exchange column. Negatively charged Si species were eluted by water. The captured REEs were separated from the other cations in the column. A solution of NaCl was used to elute the cations and most of the REEs, which were strongly adsorbed in the column, were eluted using a solution of diethylenetriaminepentaacetic acid (DTPA). In this separation process, high purity SiO2 (>99%), Al(OH)3 (>99%), and Fe(OH)3(>95%) were produced. The eluted DTPA-REEs solution was then loaded in a cation exchange column. The REEs accumulated in the column could be further separated into pure REE fractions using a ligand-assisted displacement chromatography method (LAD), instead of the conventional liquid-liquid extraction method. Detailed rate model simulations were developed for LAD and verified with experimental and literature data. The dynamic column profiles in simulations showed that a prestaurant which has a higher ligand affinity and a lower sorbent affinity than REEs is required to develop an isotachic train in LAD. When a constant-pattern isotachic train is developed, high concentration bands with high purity and high yield can be achieved. Further increase in column length is not needed. Thus, if purity, yield, sorbent, and ligand are fixed, the constant-pattern state gives the highest sorbent productivity and the highest ligand efficiency. It is critical to develop a method to find the general conditions required for developing constant-pattern states.

Degree

Ph.D.

Advisors

Wang, Purdue University.

Subject Area

Atomic physics|Design|Environmental management|Physics

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