Process development for the recovery of rare earth elements and critical metals from an acid mine leachate

[Display omitted] •REEs, Cu, Zn, Ni and Co recovery from an acid mine leachate was investigated.•A product containing >98% of rare earth oxides was obtained by precipitation.•Cu and Zn concentrates containing 60% CuS and 58% ZnS were obtained.•Co and Ni remained in the residual solution after precipitation.•An integrated process was developed based on the experimental results. Acid mine leachate (AML) may be a significant source of rare earth and other critical elements needed for the manufacturing of advanced electronics and renewable energy technologies. A systematic study was performed on a natural leachate collected from a coal preparation plant that treated bituminous coal containing elevated amounts of pyrite. The leachate contained 1.96 ppm total REEs, 2.52 ppm Zn, 2.15 ppm Ni, 1.22 ppm Cu, 0.77 ppm Co, and 25 ppm Mn. Sequential precipitation using simple pH control generated a pre-concentrate containing 0.82% total REEs, 1.08% Zn, 0.91% Ni, 0.50% Cu, 0.34% Co, 7.1% Mn. The pre-concentrate was further treated by re-dissolution using a 10 M HNO3 solution, which resulted in a solution pH of 1.5. The addition of oxalic acid to selectively precipitate the REEs followed by roasting of the precipitate generated a product containing >98% rare earth oxides. More than 95% of the Cu and Zn were recovered from the residual liquid using Na2S at pH 2 and 3, respectively. The CuS and ZnS contents in the corresponding concentrates were 60% and 58%, respectively. The majority of the Co and Ni remained in the residual liquid. Based on these findings, a process flowsheet was developed to recover the REEs and critical metals from AML.