A. Gavrilenya, I. Alexandroff
Sharp Pulse,
United States
Keywords: rare earth elements, coal fly ash, metallurgical slag, mining tailings, pulse plasma, comminution
Summary:
Abstract The growing demand for critical minerals and rare earth elements (REEs) necessitates more energy-efficient extraction technologies. Industrial waste streams such as coal fly ash, metallurgical slag, and mining tailings contain valuable minerals, but conventional mineral processing approaches are energy-intensive, costly, and inefficient in liberating these resources. Pulse plasma (PP) comminution offers an innovative alternative, leveraging high-voltage electrical discharges in a slurry to create explosive plasma sparks. These induce selective mineral liberation by generating intense pressure shockwaves (up to 2 GPa), temperature spikes, cavitation effects, and electromagnetic field variations. Unlike conventional methods, which fracture solids randomly, PP selectively fractures minerals along phase boundaries, leading to more efficient subsequent processing with higher mineral recovery rates, reduced energy consumption during smelting, and more environmentally benign and economically efficient leaching processes. Despite its advantages, earlier PP technologies faced scalability and energy efficiency challenges. This presentation introduces Sharp Pulse’s next-generation PP technology, which significantly improves energy efficiency and enables industrial-scale adoption through a low-inductance generator design and continuous-flow processing system. Technological Innovation Pulse plasma comminution fractures solids through ultra-short, high-voltage discharges, directing energy into solid phases for efficient mineral liberation. Sharp Pulse's low-inductance PP generator and electrode system achieves over 100 GA/s current rise rates, generating steep pressure shockwaves (up to 2 GPa in <0.4 µs) while reducing overall energy needs. This process: • Enhances efficiency by concentrating energy where needed, reducing waste. • Induces brittle cracking in ductile materials (e.g., steel, aluminum) via ultra-high strain rates. • Minimizes operational complexity compared to previous high-voltage PP systems. To ensure scalability, we have developed a continuous-flow system integrating multiple PP generators, achieving a processing capacity of up to 1 Mt per year. Experimental Validation & Case Studies Recent tests demonstrate that PP comminution improves energy efficiency by 25–75% over mechanical grinding and increases mineral recovery by 50–160%. Key results include: 1. Polymetallic Tailings Processing o Higher liberation efficiency for Cu, Zn, and Au from mining tailings. o Financial feasibility supports commercial viability of large-scale adoption. 2. Comminution of Hard Materials & Fine Powder Production o Achieved sub-micron particle sizes for boron carbide (B4C), titanium alloys, and diamond powders. o Demonstrated superior energy efficiency over traditional methods. Conclusion Pulse plasma comminution represents a disruptive innovation in critical mineral processing, offering a scalable, efficient, and environmentally friendly alternative to traditional high-energy methods. Our findings indicate substantial gains in energy efficiency, mineral recovery, and economic feasibility, making PP technology a key enabler of sustainable resource extraction from industrial waste streams. At TechConnect 2025, we seek to engage industry leaders, national labs, and investors to accelerate commercialization and establish partnerships for large-scale deployment.