International Exercise on the Analysis of Uranium Ore Concentrates for Nuclear Forensics
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Chemistry - Radiation chemistry, radiochemistry, a↗
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Flotation of Bastnaesite Ore Using Novel Collectors
Interest in rare earth elements (REEs) has increased due to their distinct properties and new applications. China currently has a monopoly on rare earth production due to the lack of an economically viable process used outside of China. Bastnaesite, a rare earth fluorocarbonate, is one of the most common minerals containing REEs, which is mostly comprised of cerium and other light REEs. The objective of this research is to find a novel collector for the beneficiation of bastnaesite through froth flotation experiments to increase the grade and recovery of rare earth oxides while rejecting the major gangue minerals. Microflotation and rougher bench flotation studies were evaluated to find optimal collector(s) from 19 possible candidates. Collector 2, 5, and 8 were the top performing collectors chosen from microflotation experiments. A design of experiment matrix was set up to evaluate the variables, variable interactions and provide a reverence matrix for future optimization studies. Collector 2 was assessed to be the optimal collector. A rougher flotation experiment produced a rare earth oxide grade and recovery of 41% and 78% respectively and a 91.5% rejection of calcite. Collector 8 and 14 also showed promising results in replace fatty acid.
Everly, Dylan↗
Application of GEM (Geologic Element Motion) to Heave Modeling of Cast Blasting, Mineral and Iron Ore Blasting.
Abstract not provided.
Preece, Dale -ext↗
US-Japan nuclear forensics analysis to identify the origins and process history of uranium ore concentrates
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Chemistry - Radiation chemistry, radiochemistry, a↗
Selective Electrochemical Recovery of Rare Earth Elements from Ore
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Di Bona, Kristin↗
Understanding neutron capture processes in uranium deposits using combined U-Sm-Nd isotopic compositions
Valuable insights into the history and evolution of a geologic deposit can be found by investigating neutron capture reactions. Thermal neutron capture reactions occur within both the samarium (Sm) and the uranium (U) systems, where 149 Sm and 235 U can capture neutrons to become 150 Sm and 236 U, respectively. Although largely unexplored, paired measurements of 150 Sm and 236 U could be important for understanding neutron capture effects within uranium ore bodies, and such measurements are potentially useful in nuclear forensics for assessing a material's provenance or mineral exploration. In this work, we refined measurement procedures of Sm isotope compositions utilizing MC-ICPMS. While geologic reference materials were found to have indistinguishable Sm isotope compositions, we found significant isotope variations consistent with nuclear field shift among synthetic Sm standards. Here, this observation highlights that future high-precision Sm isotope investigations need to carefully evaluate synthetic standard(s) against geologic reference materials until an unfractionated and agreed-upon standard is identified. Here, we applied this method to a set of nine uranium ores from the South Australian Beverley North uranium deposits. Although 236 U excesses had been previously reported for these U ores, we found no measurable isotopic shifts in 149 Sm- 150 Sm at the current level of precision (±5 parts per million). One possible explanation for this disparity in the observed neutron capture signatures between U and Sm is that the source(s) of the U and Sm in these ores may be decoupled. This is consistent with the finding that these ores have variable 143 Nd/ 144 Nd, thus demonstrating that diverse sources were involved in the formation of the Beverley North deposits. Alternatively, this deposit may be too young (<50Ma) to have accumulated measurable neutron capture effects in Sm to be detected with the methods employed here.
Mineral exploration↗
Developing a Coal to Products Technology Portfolio
At Ramaco Carbon we are working to bring into existence a new carbon economy with the mottos “coal is too valuable to burn” and “no molecule left behind.” Our research focus is using coal (carbon ore) as a feedstock for a variety of high-value carbon products. We have developed a process and manufacturing technology portfolio including carbon fiber, porous carbons, nano-structured carbons (bulk graphene), building products, monolayer graphene, and rare earth elements (REEs). A review of these product lines, the associated processes, and economics will provide insight into the value of carbon ore as a feedstock for high-value and specialty products. We will present our current progress in manufacturing and tailoring the properties of porous carbons and nano-structured carbon to enhance existing products and produce novel products. Included is a discussion of the properties of carbon fiber derived from direct liquefaction of sub-bituminous coal, and from pitches produced by pyrolysis and solvation by supercritical CO2. New processes for converting carbon ore into structural building materials and monolayer graphene and the evaluation of REE deposits in a Powder River Basin thermal coal reserve will also be described. The presentation will provide a review of our carbon ore to products technology portfolio and the economic advantages of using carbon ore as a feedstock for advanced carbon products and several associated end use applications.
01 COAL, LIGNITE, AND PEAT↗
Developing a Coal to Products Technology Portfolio
At Ramaco Carbon we are working to bring into existence a new carbon economy with the mottos “coal is too valuable to burn” and “no molecule left behind.” Our research focus is using coal (carbon ore) as a feedstock for a variety of high-value carbon products. We have developed a process and manufacturing technology portfolio including carbon fiber, porous carbons, nano-structured carbons (bulk graphene), building products, monolayer graphene, and rare earth elements (REEs). A review of these product lines, the associated processes, and economics will provide insight into the value of carbon ore as a feedstock for high-value and specialty products. We will present our current progress in manufacturing and tailoring the properties of porous carbons and nano-structured carbon to enhance existing products and produce novel products. Included is a discussion of the properties of carbon fiber derived from direct liquefaction of sub-bituminous coal, and from pitches produced by pyrolysis and solvation by supercritical CO2. New processes for converting carbon ore into structural building materials and monolayer graphene and the evaluation of REE deposits in a Powder River Basin thermal coal reserve will also be described. The presentation will provide a review of our carbon ore to products technology portfolio and the economic advantages of using carbon ore as a feedstock for advanced carbon products and several associated end use applications.
01 COAL, LIGNITE, AND PEAT↗
Evidence for metal sources, fluid-mixing processes, and S isotope recycling within the feeder zone of an Irish type Zn-Pb deposit
The origin and evolution of fluids in Irish-type Zn-Pb deposits remains debated, particularly regarding the mobility of metals such as Cu and Ni, sources of sulphur, and the role of fluid mixing and replacement. The Lisheen Zn-Pb deposit, Ireland, offers a well-defined natural laboratory to investigate these questions. While most studies have focused on the Waulsortian Limestone Formation, the primary sulphide host, less is known about mineralisation in underlying units, such as the Lisduff Oolite Member (LOM). The LOM displays enrichment in Cu and Ni and displays intense replacement textures compared to other hosts at Lisheen, making it an ideal target for studying metal mobility and sulphur recycling in carbonate-hosted systems. Through characterising and studying LOM-hosted sulphides, valuable insights into mineralisation processes, especially related to Cu-Ni metals, can be defined. This study integrates petrography, EMPA, and in situ sulphur isotope (δ 34 S) analysis to investigate sulphide paragenesis, mineral chemistry, and fluid evolution across LOM ore zones. Results reveal a multistage mineralising system involving extensive replacement of early pyrite (Py0, δ 34 S = −28.4 to −21.9 ‰) by sphalerite and galena, with zoned pyrite (Py1) enriched in As-Cu-Ni-Tl. The δ 34 S values and trace element trends indicate mixing between hydrothermal and bacteriogenic sulphur-rich fluids, with evidence for sulphur recycling during replacement. Pyrite textures and compositions capture this evolving fluid regime, with trace element enrichment linked to paragenetic stage. The steel ore region, adjacent to major fault intersections, records intense hydrothermal fluid interaction, hosting Ni- and As-rich phases such as nickeline, gersdorffite, and arsenopyrite. These findings highlight the importance of structural controls and fluid mixing in metal transport and deposition, positioning the LOM as a key stratigraphic unit for understanding ore-forming processes in Irish-type systems. These results have implications for targeting similar carbonate-hosted systems globally, especially where deeper or structurally complex ore zones remain underexplored.
58 - GEOSCIENCES↗
Reduction kinetics of hematite powder using argon/hydrogen plasma with prospects for near net shaping of sustainable iron
Direct reduction of iron ore using hydrogen plasma is being explored as a potential solution to decarbonize the iron and steel sector. The current state-of-the-art demonstrated reduction of hematite pellets via hydrogen plasma using Ar + 10% H 2 but had slow reduction kinetics, requiring 30 minutes of plasma exposure for complete reduction. Here we show that using hematite in a powder form, easily obtainable from beneficiated ore, results in 10× faster kinetics using plasma generated from Ar + 2% H 2 shielding gas compared to the current state-of-the art. Additionally, the increased kinetics using powders and a dilute hydrogen concentration can enable the use of advanced manufacturing techniques like blown powder directed energy deposition using a plasma tungsten arc welding torch to manufacture near net shape components directly from the ore concentrates. This ore to part approach will also reduce the emissions associated with downstream processes like rolling, forging, and machining, thereby further aiding in the sectorial decarbonization efforts.
36 MATERIALS SCIENCE↗
Correlating chemistry and mass transport in sustainable iron production
Steelmaking contributes 8% to the total CO 2 emissions globally, primarily due to coal-based iron ore reduction. Clean hydrogen-based ironmaking has variable performance because the dominant gas–solid reduction mechanism is set by the defects and pores inside the mm- to nm-sized oxide particles that change significantly as the reaction progresses. While these governing dynamics are essential to establish continuous flow of iron and its ores through reactors, the direct link between agglomeration and chemistry is still contested due to missing measurements. In this work, we directly measure the connection between chemistry and agglomeration in the smallest iron oxides relevant to magnetite ores. Using synthesized spherical 10-nm magnetite particles reacting in H 2 , we resolve the formation and consumption of wüstite (Fe 1-x O)—the step most commonly attributed to whiskering. Using X-ray diffraction, we resolve crystallographic anisotropy in the rate of the initial reaction. Complementary imaging demonstrated how the particles self-assemble, subsequently react, and grow into elongated “whisker” structures. Our insights into how morphologically uniform iron oxide particles react and agglomerate in H 2 reduction enable future size-dependent models to effectively describe the multiscale aspects of iron ore reduction.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
A Zero-Emission Process for Direct Reduction of Iron by Hydrogen Plasma in a Rotary Kiln Reactor
This project’s goal was to demonstrate a hydrogen plasma (H-plasma)-rotary kiln process for reducing iron ore to iron as part of the steel manufacturing process. The H-plasma provides a greater thermodynamic driving force for reducing iron ores than thermal processes such as the DRI process, enabling lower reaction temperatures. We estimated that our process technology can reduce energy consumption by 45% compared to the blast furnace process and ~15% compared to the DRI process. Steel manufacturing produces about 1.8 tons of CO2/ton of steel with iron ore reduction accounting for about one-third of the CO2 produced in the overall manufacturing process. We estimated our process has the potential to reduce GHG emissions from ironmaking by 35% with today’s grid and by up to 88% with a future low-carbon grid while being cost competitive with the current blast furnace route. We demonstrated reduction of hematite and magnetite rich materials at temperatures from 600 to 800°C. We achieved 90-95% metallization on 100 gr samples in batch reduction experiments in the H-plasma rotary kiln furnace at 600-650°C. Attempts to perform tests in a continuous operation mode identified problems with the ore feed mechanism. We identified solutions but there was not time nor budget to correct these for this project
36 MATERIALS SCIENCE↗
A Zero-Emission Process for Direct Reduction of Iron by Hydrogen Plasma in a Rotary Kiln Reactor
This project’s goal was to demonstrate a hydrogen plasma (H-plasma)-rotary kiln process for reducing iron ore to iron as part of the steel manufacturing process. The H-plasma provides a greater thermodynamic driving force for reducing iron ores than thermal processes such as the DRI process, enabling lower reaction temperatures. We estimated that our process technology can reduce energy consumption by 45% compared to the blast furnace process and ~15% compared to the DRI process. Steel manufacturing produces about 1.8 tons of CO2/ton of steel with iron ore reduction accounting for about one-third of the CO2 produced in the overall manufacturing process. We estimated our process has the potential to reduce GHG emissions from ironmaking by 35% with today’s grid and by up to 88% with a future low-carbon grid while being cost competitive with the current blast furnace route. We demonstrated reduction of hematite and magnetite rich materials at temperatures from 600 to 800°C. We achieved 90-95% metallization on 100 gr samples in batch reduction experiments in the H-plasma rotary kiln furnace at 600-650°C. Attempts to perform tests in a continuous operation mode identified problems with the ore feed mechanism. We identified solutions but there was not time nor budget to correct these for this project
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Canonsburg, Pennsylvania, UMTRCA Title I Disposal Site 35 Years Postclosure (1985-2020) - 20288
The DOE Office of Legacy Management (LM) Canonsburg, Pennsylvania, Disposal Site is a former uranium ore-processing site located in the borough of Canonsburg and an important part of US history. For 46 years (1911-1957), the site processed ore, for vanadium, radium and then uranium. Soils and groundwater beneath the site were contaminated by the milling operations. The 15-hectare (37-acre) site is owned by the US government and managed by LM, which serves as the federal land manager and steward of cultural, historical, and natural resources at Cold War legacy sites that have been successfully cleaned up to remedial standards. In 1978 Congress directed DOE to remediate 22 inactive uranium-ore processing sites under the Uranium Mill Tailings Radiation Control Act (UMTRCA), in accordance with standards promulgated by the US Environmental Protection Agency in Title 40 CFR Part 192 (40 (CFR 192). Subpart B of 40 CFR 192 regulates the cleanup of contaminated groundwater at the processing sites. The radioactive materials were encapsulated in US Nuclear Regulatory Commission (NRC)-approved disposal cells, and the NRC general license for UMTRCA Title I sites is established in 10 CFR 40.27. Canonsburg was the first site to be remediated under UMTRCA. From 1983 to 1985, the Canonsburg site underwent cleanup under this US law that provides for the safe and environmentally sound disposal, long-term stabilization, and control of uranium mill tailings in a manner that minimizes or eliminates radiation health hazards to the public. The site is unique in that it is one of only two UMTRCA Title I sites in the eastern half of the United States, the other site being the Burrell, Pennsylvania, Title I Disposal Site, a vicinity property to the Canonsburg site. It has been 35 years since the disposal cell at the Canonsburg site was completed. This paper discusses the many efforts that have been taken to maintain the site and presents some of the lessons learned concerning the long-term care of the site. The discussion includes but is not limited to the following: (1) Preserving site history so the community can better appreciate and understand the site. (2) Community outreach efforts, and the importance of maintaining transparency of environmental monitoring results with the community. (3) Pursuing reuse opportunities that offer the potential for improving the community. (4) Remaining engaged with the local community. (5) Remaining proactive in the long-term care of the site. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Electrical and Spectroscopic Diagnostics as Real‐Time Metallization Indicators During Hydrogen Plasma Smelting Reduction
This study investigates the hydrogen (H 2 ) plasma reduction process of direct-reduced-iron-grade hematite ore at different arc currents (100–200 A) in an Ar–5% H 2 atmosphere at 0.9 bar. Iron ore samples (10 g) were exposed to a plasma arc, and the reduction/metallization kinetics were analyzed over fixed time intervals. Electrical diagnostics revealed that the arc voltage exhibited takeover-mode oscillations which were suppressed at higher currents due to stronger electromagnetic coupling. The voltage dropped significantly as metallization approached ∼95%, linked to increased electrical conductivity of the metallic iron (Fe) in the ore as well as Fe evaporation into the arc, lowering the arc resistance. A simplified Elenbaas–Heller model supported this explanation and confirmed that Fe vapor concentration enhances plasma conductivity. Optical emission spectroscopy focused on the plasma–metal interface revealed the plasma's optically thick nature, as the primary Fe I 526.95 nm line experienced self-absorption. However, weaker Fe I lines (404.58, 438.35 nm) normalized to Ar I 696.5 nm provided a reliable proxy for metallization. These diagnostics, electrical and spectroscopic, effectively track metallization in real-time during H 2 plasma smelting reduction.
08 HYDROGEN↗
Technoeconomic Analysis of Steel Production with Electric Thermal Energy Storage
The iron and steel industry is an important manufacturing sector and one of the largest energy consumers in the United States and globally. Hydrogen direct reduction of iron ore (H2DRI) is considered a promising process that could enhance domestic steel production. This process requires hydrogen inlet temperatures up to 950 degrees C to drive the endothermic reduction of the iron ore pellets. In this work we investigate the technoeconomic performance of an H2DRI plant using electric thermal energy storage (ETES) technologies for the hydrogen heating, compared to conventional natural gas fired heaters, hydrogen fired heaters, and electric hydrogen heaters. A technoeconomic analysis framework for the plant is developed and used in multiple case studies, covering different hydrogen prices, grid electricity profiles, and financing scenarios. The levelized cost of steel production is found out to be in the range of $775-950/mt, which is mostly inside the benchmarked steel price of $941/mt. ETES-based hydrogen heating is found to be in par with conventional natural gas fired heaters, and cheaper than hydrogen fired heaters and electric hydrogen heaters. The major cost drivers are the iron ore and hydrogen feedstock, followed by the hydrogen compression and heating capital. Several insights and suggested future directions are identified.
08 HYDROGEN↗
Uranium Oxide Synthetic Pathway Discernment through Unsupervised Morphological Analysis
We present a novel unsupervised machine learning method for quantitative representation of scanning electron micrographs and its applications and performance for nuclear forensic analysis of uranium ore concentrates. The method uses a vector quantizing variational autoencoder followed by a histogram operation to encode a micrograph into a single dimensional representation, called the latent vector. The method requires no extant labeling of the data and can be applied over large datasets of micrographs with minimal human interaction. The representations generated are broadly descriptive of each micrograph and the microstructure of the material imaged. In the case of uranium ore concentrate analysis, the representations were amenable to processing reagent and ore concentrate species classification with accuracy of 81:8%, which is competitive with state-of-the-art supervised networks. The representations were also used to classify previously unseen processing routes, were able to classify imaging parameters such as magnification (to 76:0% accuracy), were able to classify fine grained process parameters such as calcining temperature (to 74:4% accuracy), and their informatic properties indicate that they are generally descriptive of the image represented. This method can be applied across microstructure analysis fields to perform quantitative analysis without the need for labor intensive and possibly biased human analysis.
Scanning Electron Microscopy, Vector Quantizing Va↗
Current nature-based biological practices for rare earth elements extraction and recovery: Bioleaching and biosorption
There is a growing demand for advancing products and renewable technologies worldwide that rely on rare earth elements (REEs), including those directly necessary for a low-carbon energy transition, national security applications, and consumer electronics. This study focuses on current nature-based biological methods (i.e., bioleaching and biosorption) for REEs extraction from electronic wastes (e-wastes) and ore deposits. Herein, comprehensive narrative and systematic reviews of bioleaching and biosorption extraction methods are performed to identify their sustainability challenges and benefits, and highlight the potential pathways that would address the existing gaps. From the narrative review, it is evident that biological methods for REEs extraction are more environmentally friendly than conventional methods currently used in the REE mining industry (e.g., acid leaching and solvent extraction). From the systematic review, it is clear that bioleaching and biosorption research has been a rapidly growing field of interest over the last 10 years, particularly for precious metals extraction (e.g., copper and gold). From both reviews, it is apparent that REEs extraction from domestic ore deposits alone is inadequate, and sustainable REEs recovery from e-wastes is also necessary to meet the growing REEs demand. It is concluded that targeted mixed REEs extraction for specific products can be a potential pathway for sustainable REEs extraction from both ore and e-wastes that would reduce separation costs and emissions from the associated use of harsh chemicals. It is further concluded that nature-based biological REE extraction solutions offer an opportunity to generate significant socio-economic and environmental benefits.
54 ENVIRONMENTAL SCIENCES↗