The goal of this project was to produce a high purity, separated (>
90%) rare earth oxide (REO) product from coal-based sources. This product was achieved using the following three steps: 1. Battelle?s ADP: The ADP process involves pretreatment of ash (milling and caustic leaching), leaching of pretreated ash with nitric acid, roasting of loaded acid solution containing REE, and water leaching of residual from roasting step, resulting in a REE pregnant solution. 2. Solvent Extraction (SX) Upgrading: The SX involves the extraction of REE from a pregnant REE solution using an organic extractant (note after extraction, the aqueous phase was a residual solution and the organic phase contained REE), and stripping of REE from the organic phase product obtained from the extraction using an acid solution (the stripped solution was the final purified product containing REE, organic traces, and traces of other metals for further separation in the electrowinning process). 3. Rare Earth Salts? (RES) Electrochemical Separation and Purification Process: The staged electrochemical process was separated REO products from the mixed REE solution. Testing by RES was also included in the investigation of options to minimize the solvent extraction steps. This report covers laboratory testing, production of a high purity coal-based REO, process design of the overall REE recovery and purification process, technoeconomic assessment (TEA), and a commercialization plan discussing the overall REE recovery and purification process.