Disclosed herein are system and methods to effectively leach coal ash with hydrochloric acid and separate an insoluble silica product and then selectively precipitate, from the leachate, a number to value-added, strategic, marketable products using a hydroxide reagent. The resulting precipitated products include iron, aluminum, magnesium, calcium, and a mixture of rare earth elements and transition metals. These can be separated as hydroxides or converted to oxides or carbonates. Using hydrochloric acid for leaching and converting the chloride to sodium chloride in the final step results in practically no waste for this process. The silica can be further purified using sodium hydroxide fusion or caustic leach methods and some minor streams from this process are recycled to minimize any waste stream. These systems and methods can be applied to a number of other industrial waste products such as red mud from the aluminum process, slag from steel furnaces, mine tailings, and other metal-bearing waste streams.

Disclosed herein are system and methods to effectively leach coal ash with hydrochloric acid and separate an insoluble silica product and then selectively precipitate, from the leachate, a number to value-added, strategic, marketable products using a hydroxide reagent. The resulting precipitated products include iron, aluminum, magnesium, calcium, and a mixture of rare earth elements and transition metals. These can be separated as hydroxides or converted to oxides or carbonates. Using hydrochloric acid for leaching and converting the chloride to sodium chloride in the final step results in practically no waste for this process. The silica can be further purified using sodium hydroxide fusion or caustic leach methods and some minor streams from this process are recycled to minimize any waste stream. These systems and methods can be applied to a number of other industrial waste products such as red mud from the aluminum process, slag from steel furnaces, mine tailings, and other metal-bearing waste streams.

Disclosed is an apparatus that is an attrition mill for grinding or comminuting ores, mine wastes, and radioactive wastes some of which may comprise metals, which may include uranium and/or cesium and/or mercury and/or thorium and/or rare earth elements. Also disclosed are processes that employ the apparatus for combined grinding and optionally leaching metals from ores and wastes. Some such methods comprise an optional step of grinding and mixing the ore or waste with a solid inorganic base with water addition or with an aqueous inorganic base, follow by a step of grinding and mixing the ore or waste with an aqueous inorganic acid with or without leaching salt addition, to solubilize the metals present in the ore or the waste. The disclosed apparatus and methods, in some embodiments, enable efficient grinding and attrition of ores substrates and mine wastes even without need for grinding media.

Disclosed is an apparatus that is an attrition mill for grinding or comminuting ores, mine wastes, and radioactive wastes some of which may comprise metals, which may include uranium and/or cesium and/or mercury and/or thorium and/or rare earth elements. Also disclosed are processes that employ the apparatus for combined grinding and optionally leaching metals from ores and wastes. Some such methods comprise an optional step of grinding and mixing the ore or waste with a solid inorganic base with water addition or with an aqueous inorganic base, follow by a step of grinding and mixing the ore or waste with an aqueous inorganic acid with or without leaching salt addition, to solubilize the metals present in the ore or the waste. The disclosed apparatus and methods, in some embodiments, enable efficient grinding and attrition of ores substrates and mine wastes even without need for grinding media.

Cathode material from exhausted lithium ion batteries are dissolved in a solution for extracting the useful elements Co (cobalt), Ni (nickel), Al (Aluminum) and Mn (manganese) to produce active cathode materials for new batteries. The solution includes compounds of desirable materials such as cobalt, nickel, aluminum and manganese dissolved as compounds from the exhausted cathode material of spent cells. Depending on a desired proportion, or ratio, of the desired materials, raw materials are added to the solution to achieve the desired ratio of the commingled compounds for the recycled cathode material for new cells. The desired materials precipitate out of solution without extensive heating or separation of the desired materials into individual compounds or elements. The resulting active cathode material has the predetermined ratio for use in new cells, and avoids high heat typically required to separate the useful elements because the desired materials remain commingled in solution.

Cathode material from exhausted lithium ion batteries are dissolved in a solution for extracting the useful elements Co (cobalt), Ni (nickel), Al (Aluminum) and Mn (manganese) to produce active cathode materials for new batteries. The solution includes compounds of desirable materials such as cobalt, nickel, aluminum and manganese dissolved as compounds from the exhausted cathode material of spent cells. Depending on a desired proportion, or ratio, of the desired materials, raw materials are added to the solution to achieve the desired ratio of the commingled compounds for the recycled cathode material for new cells. The desired materials precipitate out of solution without extensive heating or separation of the desired materials into individual compounds or elements. The resulting active cathode material has the predetermined ratio for use in new cells, and avoids high heat typically required to separate the useful elements because the desired materials remain commingled in solution.

A method for removing sulfate iron-containing compounds from a low- to moderate-temperature metal sulfide leach circuit (1) is disclosed. A reactor (6) within a chloride leach circuit (5) and which is preferably maintained at a temperature between 20 and 150 degrees Celsius may be provided with a catalyst (4) comprising a material selected from the group consisting of: colloidal hematite, colloidal goethite, particulate containing FeOOH, particulate containing α-FeOOH, particulate containing γ-FeOOH, particulate containing Fe.sub.2O.sub.3, particulate containing α-Fe.sub.2O.sub.3, particulate containing γ-Fe.sub.2O.sub.3, particulate containing Fe.sub.3O.sub.4, particulate containing Fe(OH)SO.sub.4, and a combination thereof. The catalyst (4) may also be used with heap leach and/or dump leach circuits (22), without limitation. Methods for using and generating the catalyst (4) are also disclosed. In some embodiments, the catalyst (4) may be used as an anti-frothing agent (e.g., for zinc leaching, without limitation).

A method to separate and recover at least one metal from a source of oxidized and/or primary and secondary sulfide ores by determining and modifying the values of the dielectric constant of the minerals source.

A method to separate and recover at least one metal from a source of oxidized and/or primary and secondary sulfide ores by determining and modifying the values of the dielectric constant of the minerals source.

The present disclosure discloses a method and device for removing iron in an iron-containing solution in hydrometallurgy. This method comprises the steps of: adding an iron-containing solution in hydrometallurgy into a reactor through a first homogenizing distributor, controlling concentration of the ferric iron in the reactor below 1 g/L, controlling pH of the solution in the reactor to be 2.5˜4, the temperature to be 65˜100° C., and the reaction duration to be 1˜3 hours, performing solid-liquid separation for the solution after reaction, and removing the iron in the iron-containing solution in hydrometallurgy in the form of goethite.