Rare earth elements are the 14 lanthanides on the periodic table, plus yttrium and scandium. These elements play a critical role in modern-day technologies such as liquid-crystal displays, GPS systems, and fiber optic cables. A majority of the mining of these elements is from China; however, due to decreasing reserves a need for alternative processes for extracting and processing rare earth elements (REEs) is becoming increasingly important. Special focus has been placed upon the identification of REEs within coal refuse, but the phase designation and speciation is not fully understood. This investigation focuses on the characterization, speciation, and morphology of REEs within fine and coarse coal refuse. During this study, physical and chemical characterization was conducted on coal refuse samples to understand characteristics, which influence REE phase designation. Experimental methods were chosen to specifically evaluate REE content and speciation across four key characteristics: size distribution, density, seam location, and thermal decomposition. Characterization of the refuse material was conducted in two campaigns: (1) an exploratory campaign, which focused on size distribution, and physical imaging of REEs within fine refuse, and (2) a detailed campaign, which utilized sequential chemical extraction methods alongside calcination to understand the phases in which REEs are present in coarse refuse. The results show that REEs within fine coal refuse are smaller than ten microns and found with phosphorus. In general, as size decreased REE content increased, likely due to increased clay content. Further conclusion could not be drawn from simple microscopic analysis. Consequently, detailed chemical characterization was conducted to fully understand REE speciation. The tests showed that a majority of REEs within coarse refuse were within insoluble species. A calcination treatment was found to greatly increase the recovery of REEs from the metal oxide fraction, thus increasing the overall soluble species contained within the coarse refuse material. / Master of Science / Due to increasing global demand and limited reserves, alternative sources for rare earth elements (REEs) have become an increasingly important research topic. REEs are a vital component of many modern technologies, including GPS systems, fiber optic cables, and LCD screens. Current mining of REEs is primarily from Chinese reserves which are becoming increasing depleted and are not strictly regulated for environmental impact. Due to these challenges, other resources of REEs are of increasing importance. Prior research has found coal and associated byproducts to have concentrations of REEs that could be economically exploited, reducing the rate of depletion of REE resources worldwide. To develop more efficient and cost-effective processing methods, fundamental information on the mineral composition of REE-bearing materials is needed. With this information, engineers can develop better processes that can specifically target REE-containing minerals while maximizing economic and environmental outcomes. This research seeks to overcome this knowledge gap through advanced material characterization and well-controlled laboratory process testing of coal refuse. The results show that REEs typically congregate in specific material fractions (e.g. fine size, moderate density), and these materials can be readily transformed through simple heat treatment. This transformation greatly improves the processability and provides a pathway for the economic recovery of REEs from coal wastes. The further development and deployment of these technologies can have societal benefits such as: more jobs, reduced reliance on foreign sources, and environmental cleanup of current coal waste deposits.

To assess strategies aimed at minimizing the release of trace elements and the impact of disposal of coal waste materials on the environment, two long-term leaching experiments of up to five months duration were performed using waste materials from two plants cleaning high and low sulfur bituminous coal. The tests evaluated the mobility of major trace elements under different disposal scenarios: (i) a static leaching test designed to simulate the quiescent conditions encountered by coal waste material stored under water in a stable impoundment, and (ii) a dynamic test to simulate waste materials exposed to the atmosphere, either in variable wet/dry storage conditions, or in unusual circumstances like those resulting from breaching of an impoundment containment wall. The results indicate that different refuse streams have different leaching characteristics due to difference in their mineralogy and the mobility of most elements is enhanced under highly alkaline or acidic conditions with a few being mobilized under both conditions, suggesting that the minimization of element mobility requires the pH value of the medium to be maintained around neutral. In addition, most of heavy metals were associated with the illite and pyrite minerals. Two strategies of treating coal refuse were evaluated: fly ash mixed with coarse refuse and co-disposal of coarse and fine refuse. Both methods were found to neutralize the pH conditions and thus reduce mobility of the trace elements in static leaching tests whereas the opposite was found from dynamic experiments. The results indicate that such controlled storage under water could retard acid generation and the mobility of trace elements.

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Coal refuse and combustion byproducts as industrial solid waste stockpiles have become great threats to the environment. Recycling is one practical solution to utilize this huge amount of solid waste through activation as substitute for ordinary Portland cement. The central goal of this dissertation is to investigate and develop a new silica-alumina based cementitious material largely using coal refuse as a constituent that will be ideal for durable construction, mine backfill, mine sealing and waste disposal stabilization applications. This new material is an environment-friendly alternative to ordinary Portland cement. The main constituents of the new material are coal refuse and other coal wastes including coal sludge and coal combustion products (CCPs). Compared with conventional cement production, successful development of this new technology could potentially save energy and reduce greenhouse gas emissions, recycle vast amount of coal wastes, and significantly reduce production cost. A systematic research has been conducted to seek for an optimal solution for enhancing pozzolanic reactivity of the relatively inert solid waste-coal refuse in order to improve the utilization efficiency and economy benefit for construction and building materials. The results show that thermal activation temperature ranging from 20°C to 950°C significantly increases the workability and pozzolanic property of the coal refuse. The optimal activation condition is between 700°C to 800°C within a period of 30 to 60 minutes. Microanalysis illustrates that the improved pozzolanic reactivity contributes to the generated amorphous materials from parts of inert aluminosilicate minerals by destroying the crystallize structure during the thermal activation. In the coal refuse, kaolinite begins to transfer into metakaol in at 550°C, the chlorite minerals disappear at 750°C, and muscovite 2M 1 gradually dehydroxylates to muscovite HT. Furthermore, this research examines the environmental acceptance and economic feasibility of this technology and found that this silica alumina-based cementitious material not only meets EPA requirements but also shows several advantages in industrial application.