Dr. Corby G. Anderson Harrison Western Professor

Bastnasite

Stibnite

THE CRITICAL ASPECT OF CRITICAL MATERIALS

Dr. Corby G. Anderson Harrison Western Professor The Kroll Institute for Extractive Metallurgy Colorado School of Mines G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Colorado School of Mines • • • • •

Est. 1874 Golden, Colorado 3 Colleges & 21 Technical Majors About 200 Faculty About 5000 Students

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“…has a unique mission in energy, mineral, and materials science and engineering…” “has the most stringent admission standards of any US public engineering school.” “ranked #1 in the World for Mining and Mineral Engineering” by Business Insider. “ranked as #1 US Engineering school” by USA Today. “average starting salary of a BSc Mines graduate is $ 10 K more than an Ivy League graduate.”

• • • •

G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Department of Metallurgical & Materials Engineering - MME  Abut 20 full time faculty members  5 Centers and Institutes: Kroll Institute for Extractive Metallurgy  Colorado Center for Advanced Ceramics  Advanced Steel Processing & Products Res. Ctr.  Center for Welding, Joining & Coating Research  Advanced Coatings & Surface Engineering Res. Ctr.

 Degrees:  PhD, MS, ME & BS in Metallurgical & Materials Engineering  PhD & MS in Materials Science  PhD & MS in Nuclear Engineering

 Students:  Graduate level : about 140  Undergraduate level: about 50 per year graduate G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Kroll Institute for Extractive Metallurgy Patrick R. Taylor Director, KIEM G.S. Ansell Distinguished Professor of Chemical Metallurgy EXPERTISE •Mineral Processing •Extractive Metallurgy •Recycling •Waste Treatment & Minimization •Thermal Plasma Processing

Edgar E. Vidal Research Associate Professor of Metallurgical and Materials Engineering EXPERTISE •Extractive and process metallurgy •Pyrometallurgy •Recycling •Waste treatment and minimization.

D. Erik Spiller Research Professor of Metallurgical nd Materials Engineering EXPERTISE •Mineral Processing •Leaching •Project management: feasibility, engineering, construction management, operationsa

Possible New Professors– to be hired to replace Dr. G.P. Martins and Dr. B. Mishra

Brajendra Mishra Director, CR3 Emeritus Professor of Metallurgical and Materials Engineering EXPERTISE •Pyrometallurgy •Electrochemistry •Materials synthesis •Waste Processing •Recycling •Molten Salt Processing

Paul B. Queneau Gerard P. Martins Adjunct Professor Emeritus Professor of Metallurgical and Materials Engineering EXPERTISE •Extractive and process EXPERTISE metallurgy Process and extraction •Pyrometallurgy metallurgy •Recycling Engineered ceramic and •Waste treatment and metal powders minimization. Electrochemical systems Corrosion Transport phenomena Reactor Design


Corby G. Anderson Harrison Western Professor of Metallurgical and Materials Engineering CSM Director, CR3 EXPERTISE •Extractive Metallurgy •Mineral Processing •Recycling • Waste Treatment & Minimization

Judith C. Gomez Research Assistant Professor of Metallurgical and Materials Engineering EXPERTISE Extractive and process metallurgy Materials synthesis Recycling Waste treatment and minimization

The Kroll Institute for Extractive Metallurgy

Dr. Patrick R. Taylor, Director KIEM George S. Ansell Department of Metallurgical & Materials Engineering, Colorado School of Mines


“KIEM - Excellence in Education and Research for the Mining, Minerals and Metals Industries” • History: The Kroll Institute for Extractive Metallurgy was established at the Colorado School of Mines in 1974 using a bequest from William J. Kroll. • This effort was led by Professor Al  Objectives: The objectives of KIEM Schlechten. For over 40 years, the are to provide research expertise, Kroll Institute has provided support for well-trained engineers to industry, a significant number of undergraduate and research and educational and graduate students who have gone opportunities to students, in the areas on to make important contributions to of : minerals processing, extractive the mining, minerals and metals metallurgy, recycling, and waste industries. minimization. G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

CRITICAL ASPECT OF CRITICAL MATERIALS

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CRITICAL MATERIALS


ALUMINUM A RARE METAL BEFORE 1887 The 10 Most Abundant Elements in the Earth's Crust Source: CRC Handbook of Chemistry and Physics, 77th Edition. Element

Abundance percent by weight

Abundance parts per million by weight

Oxygen

46.1%

461,000

Silicon

28.2%

282,000

Aluminum

8.23%

82,300

Iron

5.63%

56,300

Calcium

4.15%

41,500

Sodium

2.36%

23,600

Magnesium

2.33%

23,300

Potassium

2.09%

20,900

Titanium

0.565%

5,650

Hydrogen

0.14%

1,400


Karl Joseph Bayer


Chateau Des Beaux, France


BAYER ALUMINA 1887 PROCESS



Electrometallurgy Hall – Heroult Aluminum Process 1887


ALUMINUM


ALUMINUM A COMMON METAL AFTER 1887


CRITICAL MATERIALS Rare Earths

Antimony Antimony


CRITICAL MATERIALS Rare Earths

Antimony


REE USES As of 2009, the USGS reports the distribution of rare earths by end use, in decreasing order, was: - chemical catalysts 22% - metallurgical applications and alloys 21% - petroleum refining catalysts 14% - automotive catalytic converters 13% - glass polishing and ceramics 9% - rare earth phosphors for computer monitors, lighting, televisions 8% - permanent magnets 7% - electronics 3% - others 3 %


Rare Earths  Total TREO abundance in earth is 220 ppm. Carbon 200 ppm ! They are widely distributed in low individual concentrations but found all together normally. There are 123 important rare earth deposits in the world and they are located in twenty countries. They occur in over 200 minerals. 95% of TREOs occur in the minerals bastansite, monazite and xenotime. G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Rare Earths Powderhorn White Earth Deposit Gunnison, Colorado - Perovskite, CaTiO3

500 Million Tons of 8% Perovskite - 0.36% TREO ! Development (hence rarity) of Ti and TREO impeded by concentration and separation not availability ! G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Example Flow Sheet – Mineral Processing – Flotation and Chemical Treatment A very complex flow sheet that requires significant energy and chemicals. Research may lead to alternative surface chemistry and flotation processes.


Rare Earths Hydrometallurgy - Rare earths are difficult to concentrate and separate as they have very similar chemical natures. - It took 160 years for scientists to isolate and identify all of them. - They have ‘lanthanide contraction’ which is the root cause of rare earth chemistry similarities. G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Rare Earths Lanthanide Contraction


Rare Earths Hydrometallurgy


Selective Hydrometallurgical IX Separation of REO

Typical Yields and Purities Of The Rare Earth Oxides Recovered Through Ion Exchange.

Ion Exchange Columns for the Separation of the Lanthanides at Michigan Chemical Corporation, St. Louis Michigan.

Separation of the Lanthanides from Cationic Exchanger DOWEX 50 with 1 M Lactate pH = 3.19, flow rate at 0.4 ml/cm2/min.


Extraction of REO from Bastnasite

HF

Once a concentrate is obtained, then the metals of interest must be extracted from the material. Several approaches are possible, usually involving calcining and acid leaching. The solutions are then subjected to ion exchange or solvent extraction for purification.


ANTIMONY


Antimony History • • • • • • •

Known in 4000 B.C. Metal known as regulus Greek for “metal not found alone” Metal is brittle - must be alloyed Early 1900’s used in munitions Automobile batteries boosted usage Flame retardants now major use


Antimony Occurrence and Mineralogy • Abundance in earth 0.2 g/t • Antimony is a chalcophile • Over 100 Antimony minerals are known • Stibnite, Sb2S3, is the predominant ore


ANTIMONY


Antimony Uses and Applications • Sb2O3 for flame retardants, pigments, and catalysts. • NaSb(OH)6 for flame retardants and glass. • Antimonial lead and alloys. • Sb2S3 in brake lines and matches. • Sb2O5 for flame retardants.


Antimony • For optical rewritable disks like DVD as a material to phase-change layer providing increase of data capacity

For low-noise refrigerators and wine cellars of recent advanced models as a mixture to materials of thermoelectric module of cooling system.

For electronic components such as IC filler and IC chips, as a flame retardant additive.

For polyester fiber as a polymerization catalyst.

For its flame retardant properties, antimony is used as an additive in the production of components for office electronic equipment such as personal computers, copying and facsimile machines For electronic components such as IC filler and IC chips, as a flame retardant.

For components of automobile such as an engine block as additives in molding and a brake pad/lining as additives for friction material, for wire coating materials,rubber materials and for the plastics in automobile interiors for its flame retardant properties.


ANTIMONY

Antimony Market Factors Global Demand is increasing as the Chinese economy continues to grow at approximately 10% per year. And the Western world is increasing the requirements on fire-proofing. In the EU Sb is a top Critical Material now and current metal and oxide prices are rising dramatically.

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ANTIMONY Worldwide known reserves are be only 2.1m tonne of Sb metal. This represents only 11 years of consumption left.

China has the majority of known metal reserves. But, China’s reserves are depleting rapidly. Antimony (Sb – stibnite) is a very scarce mineral G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Economics of Antimony

Few Published Prices Chinese Dominate Industry for the Past 25 Years


Zhao Tian Cong


ANTIMONY Typical Stibnite Ore Mineral Processing Results Operation

Conc. Grade, % Sb

Tails Grade, % Sb

Recovery, %

Hand sorting

Ore Grade, % Sb 2.25

7.80

0.12

95.95

Heavy media

1.58

2.65

0.18

95.11

Flotation

3.19

47.58

0.21

93.97

Average

2.68

19.44

0.18

94.11


Pyrometallurgy of Antimony • Generally grade determines process •

5 - 25% Sb - volatilized to Sb2O3

• 25 - 40% Sb - smelted in blast furnace • 45 - 60% Sb - liquation or iron precipitation



Hydrometallurgy of Antimony

• Alkaline Sulfide system • Acidic Chloride system


Sunshine Antimony Process

First built in 1942 as part of US Government need for Critical Materials for the US WWII effort. Torn down in 2002 due to Chinese market domination and subsequent low global Sb prices. G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING


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CRITICAL ASPECT OF CRITICAL MATERIALS • 50 % of All Experienced North American Mineral Processing and Extractive Metallurgical Engineering Expertise Will Retire In Less Than 10 Years. • In North America Only About A Half Dozen Schools Teach Or Do Substantive Research In Extractive Metallurgy. • No North American School Offers An Accredited Distinct Mineral Processing Or Extractive Metallurgy Engineering Degree Any More. G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING



CRITICAL ASPECT OF CRITICAL MATERIALS Alphabetical List of ABET Accredited Mining and Metallurgical Engineering Programs in the United States. B.S. Mining Engineering

B.S. Metallurgical Engineering

Colorado School of Mines

University of Arizona

Colorado School of Mines

Missouri University of Science and Technology

University of Kentucky

Missouri University of Science and Technology

Montana Tech of the University of Montana

University of Nevada-Reno

Montana Tech of the University of Montana

New Mexico Institute of Mining and Technology

University of Utah

South Dakota School of Mines and Technology

Pennsylvania State University

Virginia Polytechnic Institute and State University

University of Alabama

South Dakota School of Mines and Technology

West Virginia University

University of Nevada-Reno

Southern Illinois University at Carbondale

University of Texas at El Paso

University of Alaska Fairbanks

University of Utah


CRITICAL ASPECT OF CRITICAL MATERIALS • There Is Only One Disticnt Metallurgical Engineering Program In North America (U of Utah). All The Rest Are Aligned With Or Subsets Of Materials, Mining Or Other Programs. •We Have Now Lost 3 Generations of Mineral Engineering Talent. • We Lost The US Bureau of Mines. G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

CRITICAL ASPECT OF CRITICAL MATERIALS • We Cannot Attract, Hire Or Retain Qualified Faculty. • The Western Australia School of Mines Just Consolidated Mining Engineering With Extractive Metallurgy. • The Camborne School of Mines Just Suspended It’s Mineral Engineering Program. • We Gave Up Our Mineral Engineering Intellectual Capacity And It Will Take A Long Time And A Lot of Effort To Regain It. G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING


How are we fixing this ?


Bastnasite

Monazite and other ores

Tailings

Phosphoric Acid

Concentrates Purified intermediates: fluorides, oxalates, carbonates, etc.

Oxides Metals & Alloys Magnets

Catalysts Electrodes Etc.


AN

ENERGY

I N N O VAT I O N

HUB


Two Guiding Principles 1. Produce more

2. Use less

• We have to address the entire materials lifecycle, going from birth through death, and beyond, to include resurrection. G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Mineral Processing/Extractive Metallurgy Mineral Processing – the utilization of methods to separate valuable minerals (or metals) from waste minerals (or recycled materials) Hydrometallurgy – the utilization of aqueous environments to remove metals from minerals (or recycled materials), to separate dissolved metals from each other, to recover metals from solution. Pyrometallurgy – the utilization of elevated temperatures to modify the chemistry of minerals, to reduce minerals to metals, to refine metals, etc. Electrometallurgy – the utilization of electricity to recover and to refine metals, etc. G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Public Perception of Extractive Metallurgy


Financial Perception of Extractive Metallurgy


Actual Extractive Metallurgy


Mining, Mineral Processing & Extractive Metallurgy – Past & Present PAST

Future?

PRESENT Geology

Geology

M ining

M ineral Processing Extractive (Chemical) M etallurgy

Education Engineering Economics

Waste Treatment, Processing & Minimization

Mining

Particulate Materials Processing Materials Chemical Processing

Physical M etallurgy

Education Engineering Economics Energy Environment

Recycle

New Materials Development

Materials Science & Engineering


Department of Metallurgical & Materials Engineering - MME Bachelor of Science


Department of Metallurgical & Materials Engineering - MME Master of Engineering 30 Graduate Level Course Credits and an Engineering Report


Department of Metallurgical & Materials Engineering - MME Master of Science 18 Graduate Level Course Credits, 18 Research Credits 1 Peer Review Publication And A Research Thesis G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Department of Metallurgical & Materials Engineering - MME

Doctor of Philosophy 36 Graduate Level Course Credits Written and Oral Comprehensive Exams Two Peer Reviewed Publications And A Research Thesis G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING

Alexandra Anderson

Allie has Master of Science and is now PhD candidate. She is from Gonzaga University in Spokane, Washington. She was working on rare earth metal reduction through molten salt electrolysis with Professor Mishra. Now she is working on computational fluid dynamics for her PhD research with Dr. Taylor.

Caelen Anderson

Caelen is from Butte, Ameriac and has earned his PhD. He earned his undergraduate degree in Metallurgical Engineering from Montana School of Mines, his MSc. in Mineral Resource Management from the Camborne School of Mines, and his MSc. in Minerals Engineering from RWTH Aachen. In his PhD thesis he worked on improving understanding of rare earth mineral surface chemistry and its application to froth flotation with Professor Taylor.


Brett Carlson

Brett is a PhD candidate from Rapid City, South Dakota. He earned his undergraduate degree in Metallurgical Engineering from South Dakota School of Mines and Technology. He is researching recycling of rare earth magnets with Professor Taylor.

Hao Cui

Hao is a PhD candidate from China. He earned his undergraduate degree from University of Technology and Science, Beijing. He completed his MSc research on the flotation of rare earth carbonate minerals and trying to find a way of depressing gangue minerals with Professor Anderson. He is now working on Recycling of Electronic Waste.


Patrick Max Eduafo

Patrick was a Ph.D. candidate from Ghana. He earned his undergraduate degree from Jacobs University in Germany. His PhD research project was completed on Recovery of Rare Earth Metals from Waste Fluorescent Lamps with Professor Mishra.

Camille Fleuriault

Camille was Master of Science candidate from Saintes, in southwestern France. She earned her Bachelor and M.E. Degrees at the National School of Geology in Nancy, France. She completed her MSc thesis on a pressure oxidation leaching project with Professor Anderson.


Joe Grogan

Joe was a Ph.D. student from Tullamore, Ireland. He earned a B.Sc. in Environmental Geochemistry from University College Dublin and a M.Sc. in Mineral Engineering from the Camborne School of Mines. His completed his PhD thesis research in zinc hydrometallurgy, corrosion control, and reagent recovery technology developed an economic process to dezinc steel scrap with Professor Anderson.

Myungwon Jung

Myungwon is a Ph.D. candidate from Seoul, South Korea. He earned his BS and MS degrees from Hongik University in South Korea. He is currently working on the recovery of valuable metals from fines with Professor Mishra.


Evody Tshijik Karumb

Eve is a Master of Science candidate who was born in the Democratic Republic of Congo (D.R.C.). She transferred to the Colorado School of Mines (CSM) where she completed her MME degree. She is working on the beneficiation and recovery of Indium from mine tailings with Professor Taylor.

Mark Manganello

Mark was a Master of Science candidate from Anderson, South Carolina. He earned his B.Sc. from CSM in Metallurgy and Materials Engineering with a focus in Physical Metallurgy and a minor in Energy. In his MSc research he worked on the recycling of flat panel displays, with a focus on recovering Indium and rare earth phosphors with Professor Taylor.


Husni Usman

Josue Nduwa Mushidi

Husni was a Ph.D. candidate from Indonesia. He earned his undergraduate degree in Metallurgical Engineering from the Bandung Institute of Technology, Indonesia. His research project was compelted on “Measuring the Efficiency of Grinding Mills as a Function of Mill Lifter Configurations and Operating Parameters” with Professors Spiller and Taylor

Josue was Master of Science student from Likasi / D.R. Congo. He earned his undergraduate degree from CSM in Metallurgical and Materials Engineering. He completed his MSc research project on Monazite Recovery by Flotation with Professor Anderson.


Doug Schriner

Doug was Master of Science candidate from Findlay, Ohio. He received a B.Sc. in Materials Science and Engineering from Michigan State University in East Lansing, Michigan. He complteed his MSC thesis research working on improving recovery in rare earth mineral flotation with Professor Anderson. He is now a PhD candidate with Dr. Taylor.

Mark Strauss

Mark was a Master’s student from Mesa, Arizona. He earned his undergraduate degree from the University of Arizona. E completed his MSc research project is the Extraction and Recovery of Rare Earth Metals from Recycled Fluorescent Lamps with Professor Mishra.


Yicheng Zhang

Yicheng was a Master of Science candidate from Beijing China. He completed his MSc thesis by working on improving recovery in rare earth mineral flotation with Professor Anderson.

Jordan Rutledge

Jordan Rutledge is Master of Science candidate. She received a B.Sc. in Metallurgical and Materials Engineering the Colorado School of Mines. She is completing her MSc thesis working on the use of tannins in mineral processing and extractive metallurgy with Professor Anderson.


Alex Norgren

Alex is a Master of Science candidate from Denver, Colorado. He received a B.Sc. in Metallurgical and Materials Engineering from the Colorado School of Mines. He is working on improving recovery in rare earth mineral physical beneficiation with Professor Anderson.

Victoria Vacarezza

Victoria is a Master of Science candidate from Chicago, Illinois. She received her BS in Materials Science from Northwestern. She is working on improving recovery in rare earth eudyalite mineral beneficiation with Professor Anderson.


Nathaneal Williams

Nathaneal is a Master of Science candidate from Carson City, Nevada. He received a B.Sc. in Metallurgical and Materials Engineering from the Colorado School of Mines. He is working on improving recovery in rare earth mineral flotation with Professor Anderson.

Dylan Everly

Dylan is a Master of Science candidate from Butte, America. He received a B.Sc. in Chemical and Biological Engineering from Montana State University. He is working on improving recovery in rare earth mineral flotation with Professor Anderson.


Hunter Sceats

Hunter is a PhD candidate from Colorado Springs, Colorado. He received a B.Sc. in Physics from Cal Tech. He is working on improving he reduction of Rare Earth oxides using plasma technology. with Professor Taylor.

Tom Boundy

Tom is a PhD candidate from California. He received a B.Sc. in Chemistry from Pepperdine. He is working on recycling of PV materials with Professor Taylor.


Sumedh Gostu

Sumedh was Master of Science candidate from India. He completed his thesis on Red Mud recycling with. Dr. Mishra

Bernard Fosu

Bernard was Master of Science candidate from Ghnha He completed his thesis on roasting of gold ores with Dr. Taylor..


Caleb Stanton

Caleb was Master of Science candidate from California He completed his thesis on recycling of Rare earth magnets with Dr. Mishra.

Matt Esquibel

Matt was Master of Science candidate from Butte, America. He completed his thesis on recycling of PV panels with Dr. Taylor.


Hill Hall, home of KIEM Please come see what we’re up to. Thank you for this opportunity to present ! The Kroll Institute for Extractive Metallurgy Department of Metallurgical and Materials Engineering Colorado School of Mines www.mines.edu

QUESTIONS ??????????????????????????????? If you want a copy of the presentation please give me a business card or email me at [email protected]


Bastnasite

Stibnite

THE CRITICAL ASPECT OF CRITICAL MATERIALS

Dr. Corby G. Anderson Harrison Western Professor The Kroll Institute for Extractive Metallurgy Colorado School of Mines G. S. ANSELL DEPARTMENT OF METALLURGICAL & MATERIALS ENGINEERING