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Browsing by Author "Ziemkiewicz, Paul F."

Now showing 1 - 5 of 5
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    Bayesian Methods for Mineral Processing Operations
    Koermer, Scott Carl (Virginia Tech, 2022-06-07)
    Increases in demand have driven the development of complex processing technology for separating mineral resources from exceedingly low grade multi- component resources. Low mineral concentrations and variable feedstocks can make separating signal from noise difficult, while high process complexity and the multi-component nature of a feedstock can make testwork, optimization, and process simulation difficult or infeasible. A prime example of such a scenario is the recovery and separation of rare earth elements (REEs) and other critical minerals from acid mine drainage (AMD) using a solvent extraction (SX) process. In this process the REE concentration found in an AMD source can vary site to site, and season to season. SX processes take a non-trivial amount of time to reach steady state. The separation of numerous individual elements from gangue metals is a high-dimensional problem, and SX simulators can have a prohibitive computation time. Bayesian statistical methods intrinsically quantify uncertainty of model parameters and predictions given a set of data and a prior distribution and model parameter prior distributions. The uncertainty quantification possible with Bayesian methods lend well to statistical simulation, model selection, and sensitivity analysis. Moreover, Bayesian models utilizing Gaussian Process priors can be used for active learning tasks which allow for prediction, optimization, and simulator calibration while reducing data requirements. However, literature on Bayesian methods applied to separations engineering is sparse. The goal of this dissertation is to investigate, illustrate, and test the use of a handful of Bayesian methods applied to process engineering problems. First further details for the background and motivation are provided in the introduction. The literature review provides further information regarding critical minerals, solvent extraction, Bayeisan inference, data reconciliation for separations, and Gaussian process modeling. The body of work contains four chapters containing a mixture of novel applications for Bayesian methods and a novel statistical method derived for the use with the motivating problem. Chapter topics include Bayesian data reconciliation for processes, Bayesian inference for a model intended to aid engineers in deciding if a process has reached steady state, Bayesian optimization of a process with unknown dynamics, and a novel active learning criteria for reducing the computation time required for the Bayesian calibration of simulations to real data. In closing, the utility of a handfull of Bayesian methods are displayed. However, the work presented is not intended to be complete and suggestions for further improvements to the application of Bayesian methods to separations are provided.
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    Characteristic Analysis of Acid Mine Drainage Precipitates for the Optimization of Rare Earth Extraction Processes
    Saber, Scott William (Virginia Tech, 2018-10-25)
    Acid mine drainage (AMD) forms when sulfur bearing rocks such as pyrite, are exposed to air and water. The oxidation of these minerals leads to the generation of sulfuric acid, which in turn mobilizes metals such as iron, aluminum, manganese, and others. If left untreated, AMD can cause severe harm to the surrounding ecosystem. By law, mining companies are required to treat AMD, often by oxidizing the contaminated water, raising the pH with a chemical additive, and precipitating the metals out of solution. Recent studies at West Virginia University and Virginia Tech have shown that AMD and the treatment precipitates (AMDp) are enriched in rare earth elements (REEs). Given the importance of REEs to modern technology, as well as potential supply restrictions, subsequent research has attempted to identify promising methods to extract and recovery REEs from AMD and AMDp. Prior studies have shown that the physical characteristics of AMDp can vary considerably from site to site, and a robust processes scheme must account for any site-specific disparities. To better understand the inherent variability of AMDp, a scientific study was commissioned to investigate a standard method of characterizing AMDp for the optimization of rare earth extraction processes. The tests developed in this work define the total acid dose needed to dissolve AMDp at various target pH points. Through the course of the study, over 150 unique AMDp samples were evaluated, and comparative analyses were conducted on samples from different sites as well as replicate samples from the same sites. The resultant dataset was analyzed using an empirical model, and a statistical analysis was conducted to correlate the model parameters and other AMDp physical properties. Relationships between elemental assays, moisture, and fitting parameters of the empirical models were found. These results ultimately led to a recommendation for future treatment of AMD and prospective sites.
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    Process Development and Techno-Economic Analysis for the Recovery of Rare Earth Elements and Critical Materials from Acid Mine Drainage
    Metivier-Larochelle, Tommee (Virginia Tech, 2023-01-17)
    Rare earth elements (REE) exhibit particular and unique properties that render them essential to technological applications. Of particular interest is their involvement in the transition toward global sustainability and their military applications. The magnetic properties of the rare earth elements is of primordial importance to sustainable development. More specifically, terbium and dysprosium are two elements with no known substitutes in critical applications and with no domestic or allied sourcing available. These elements are currently mined by in-situ leaching of ion-absorbed clays, mostly from illegal operations in Myanmar financed by Chinese companies. The demand from both elements, and for the other magnet rare earths is projected to growth at very high rates through 2035 while the world undergoes a transition toward sustainability, and a drastic reduction in greenhouse gases emissions. Our team has been evaluating the potential of acid mine drainage (AMD) as a source of rare earth elements and critical materials (CM). Acid mine drainage is the result of in-situ generation of sulfuric acid due to the weathering of sulfide ores. It is a significant legacy environmental issue and one of the largest pollutants in many mining districts throughout the world. The objective of the present work is to provides a roadmap for the utilization of AMD as a critical material feedstock to preserve the independence of the United States of America with regards to these materials. To that effect, a fundamental economic assessment of REE/CM recovery from AMD using a network sourcing strategy in addition to a robust, flexible feedstock separations and refining facility was undertaken. A techno-economic analysis of the extraction, refining, separation and reduction to metal is presented along with a sensitivity analysis.The results of this analysis show that, with the exception of the minimum price scenario, all operational configurations have positive economic indicators with rates of return varying from 25% to 32% for the contemporary price scenario. This is primarily due to the very high enrichment in terbium and dysprosium of AMD. The optimal configuration was determined to be production of Co, Mn, and all REEs except for mischmetal, which is not recovered. Sensitivity analysis and Monte Carlo Simulation show that capital cost and HCl consumption are the two major factors influencing rate of return, thus indicating opportunities for future technology development and cost optimization. In order to reduce both the capital and operation cost of the facility, alternative ionic liquids extractants based on conventional acidic extractants where synthesized and investigated. The results show that the ionic liquids varied in performance, with [c101][D2EHP] and [c101][EHEHP] performing poorer than their conventional counterparts and [c101][c572] performing better. The performance of [c101][c572] was 13% superior to Cyanex 572, 20% superior to EHEHPA and 27% superior to D2EHPA the current commercially used extractants. Recommendations for further study on [c101][c572] include stripping tests, continuous pilot testing, and techno-economic analysis. The test work revealed that zinc and to a lesser extent calcium were significant deleterious elements in the solvent extraction circuit, and that selective removal would significantly reduce the acid-base consumption of the separation circuit. A process was developed to selectively remove calcium and zinc from AMD-derived feedstock and from REE products. The ammonium chloride leach process offer many advantages, including the possibility of closing the cycle by using carbon dioxide sequestration as a step to regenerate the ammonium chloride in a zero-discharge process.
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    Production of High-Grade Mixed Rare Earth Oxides from Acid Mine Drainage via Solvent Extraction: Laboratory-Scale Process Development
    Liu, Shushu (Virginia Tech, 2020-01-22)
    Several recent studies have shown that acid mine drainage (AMD) may be a promising source of rare earth elements (REEs), which are essential feedstocks for many high tech applications and defense products. AMD is a longstanding environmental challenge and is currently the primary pollutant of water in the Appalachian coal mining region. Acid generated during the coal mining process tends to leach several transition metals from the surrounding rock strata. While iron, aluminum, and manganese have traditionally been noted as the predominant metals in AMD, recent studies have also shown that REEs are also present, albeit in trace concentrations, often less than 5 μg/L. The recovery of REEs from AMD can be both an economic and environmental advantage; however, the low REE concentrations and high contamination from other metals makes the concentration and purification of REEs quite difficult. This research seeks to develop and optimize a process capable of producing mixed rare earth concentrates with purities exceeding 90% from an AMD feedstock. Parallel efforts by other members of the research team showed that a solid preconcentrate, nominally 0.1 to 2% REE, can be readily produced from AMD; however, that pre-concentration process cannot provide the further enrichment needed to generate high purity oxides suitable for downstream markets. In this project, solvent extraction was investigated as secondary process used to further enrich the low grade preconcentrate to a purity exceeding 90%. Initially, laboratory-scale batch solvent extraction tests were performed on synthetic REE solutions to determine the influence of various process parameters (e.g. pH, extractant dosage, diluent type, and feedstock concentration). Next, the separation of REEs from major AMD gangue elements was investigated using synthetic leachate solutions with concentrations similar to those expected from the pre-concentrate samples. This process showed that the grade targets could easily be met when combining optimal parameters from each step. From this preliminary work with synthetic solutions, an optimal SX process was developed and validated using a real leachate generated from a pre-concentrate sample. By integrating leachate preparation, solvent extraction, scrubbing, stripping, and oxalic acid precipitation, an oxide containing 90.5% rare earth oxides was generated. Details on the process development, experimental optimization, and opportunities for process improvement are described.
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    Review of Passive Systems for Acid Mine Drainage Treatment
    Skousen, Jeffrey G.; Zipper, Carl E.; Rose, Arthur; Ziemkiewicz, Paul F.; Nairn, Robert; McDonald, Louis M.; Kleinmann, Robert L. (2017-03)
    When appropriately designed and maintained, passive systems can provide long-term, efficient, and effective treatment for many acid mine drainage (AMD) sources. Passive AMD treatment relies on natural processes to neutralize acidity and to oxidize or reduce and precipitate metal contaminants. Passive treatment is most suitable for small to moderate AMD discharges of appropriate chemistry, but periodic inspection and maintenance plus eventual renovation are generally required. Passive treatment technologies can be separated into biological and geochemical types. Biological passive treatment technologies generally rely on bacterial activity, and may use organic matter to stimulate microbial sulfate reduction and to adsorb contaminants; constructed wetlands, vertical flow wetlands, and bioreactors are all examples. Geochemical systems place alkalinity-generating materials such as limestone in contact with AMD (direct treatment) or with fresh water up-gradient of the AMD. Most passive treatment systems employ multiple methods, often in series, to promote acid neutralization and oxidation and precipitation of the resulting metal flocs. Before selecting an appropriate treatment technology, the AMD conditions and chemistry must be characterized. Flow, acidity and alkalinity, metal, and dissolved oxygen concentrations are critical parameters. This paper reviews the current state of passive system technology development, provides results for various system types, and provides guidance for sizing and effective operation.