The supply shortage of rare earth elements (REEs) for use in numerous high-tech applications has become an incentive for the prospecting of REEs from coal and coal discard. In this study, an optimised leaching process for the recovery of REEs from coal using the Design Expert (DOE) is reported. Response surface methodology (RSM) was used to investigate the effect and to determine the optimal leaching parameters for the two non-calcined coal samples. An optimised REE leaching recovery of 18.95% and 41.35% was obtained for the non-calcined Run-of-Mine (ROM) coal and discard coal, respectively. This optimised recovery was obtained as the HCl concentration increased from 0.5 M to 2 M, leaching temperature increased from 30 °C to 50 °C, whilst the solid:liquid ratio decreased from 40 g/L to 10 g/L. Statistical analysis indicated that the leaching parameters studied were important and controlled the REE leaching recovery model. Optimisation results also indicate that the calcined coals at 700 °C have the highest leaching recovery of 94.73% (ROM) and 98.17% (discard), respectively. Calcination also increased the concentration of REEs in the ROM sample from 225 ppm to 347 ppm and discarded the sample from 245 ppm to 363 ppm at 700 °C. Given the effect of the lixiviants investigated, the leaching efficiency of HClO4 for REE recovery was significantly lower than HCl and HNO3 under optimal leaching conditions. The discard coal used in this study had a significantly higher potential for REE recovery than ROM coal because it had a higher REE abundance and greater recovery.
Recycling coal-based waste (CBW) into composites suitable as a building material might be a necessary response to combat its risk to the environment. Therefore, the objective of this study was to investigate the microstructure and performance of coal composites produced from CBW and polysiloxane polymer (SPR-212). Four types of CBW that differ in physicochemical properties were examined. Fourier transform infrared spectroscopy results indicated that the higher the intensity of the C=C bonds in the CBW, the higher the pyrolysis mass loss and shrinkage experienced by the composites during pyrolysis. The continuous operating temperature of the composites is up to 600 °C. However, at temperatures above 600 °C, composites containing carbon content greater than 36% manifested dramatic degradation. Pyrolysis mass loss in the range of 5.28 to 29.62% was obtained for all the composites. The density range of the composites is between 1.5 and 1.9 g per cubic centimetre. The water absorption of all the composites is within the range of 0 to 25% and is comparable to many building materials. Notably, the composites containing total carbon less than 10% registered a water contact angle greater than 90°, indicating the low wettability of their surface. Furthermore, composites that embodied the highest total carbon (63%) displayed the worst structural property. The findings of this study lay the foundation for further development of high-quality structural coal composites from CBW and the SPR-212 preceramic polymer through optimisation of the processing conditions.
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