From Ashes to Riches: Microscale Phenomena Controlling Rare Earths Recovery from Coal Fly Ash

Coal fly ash is an alternative source of rare earth elements (REEs), which are critical in modern energy and electronic technologies. Current hydrometallurgical processes, however, yield variable recovery rates because of the limited understanding of the microscale phenomena controlling the extraction of REEs from fly ash. This work investigates the microscale processes that dictate the recovery of REEs from ash particulates via a spatiochemical analysis. We find that REE-bearing minerals are hosted in three modes with distinct recovery mechanisms: (i) REEs encapsulated in dense particles are recovered via the cation exchange between matrix metals (Al, Ca, Mg, etc.) and solution cations, (ii) REEs within permeable particles are recovered via intraparticle pore-scale fluid flow, and (iii) discrete and surface-bound REE-bearing minerals are recovered via direct exposure to reagents. The role of metal content and the limiting transport mechanisms are further probed for dense particles, the predominant mode of occurrence. This study highlights, for the first time, how the morphology and the elemental makeup of the ash matrix play a critical role in the accessibility of REEs, furthering the knowledge base required for the design of cost-effective and environmentally benign REEs recovery techniques.