M.C. Hargett, K.M. Khozan
CVMR (USA) Inc.,
United States
Keywords: modernization, OPEX,CAPEX, Critical Materials, Process Size Reduction, REE, Nickel
Summary:
Modernization of Conventional Critical Materials Production to Achieve Reduction in CAPEX, OPEX and the Scale of Process Systems Presented by: Michael C. Hargett, PMgr, President of CVMR (USA) and Kamran M. Khozan Ph.D., CEO, CVMR Corporation Productive extraction of critical materials requires innovation in process design, novel chemistries, and integration of advanced controls for systems that can be economically scaled to reliable production and high quality operations. Commonly, the innovation begins at a bench or laboratory scale and progresses to an “industrial” scale satisfying production objectives and business plans. For some industrial operations, large production investments may not accept progressions in process engineering or controls without system failure, expansion of product demand beyond capacity, or evolving quality standards that make the older systems obsolete. Occasionally, a variation in the system application and form of product may generate a demand requiring a new configuration of the process. This discussion presents an adaptation of critical materials manufacturing processes for refining metals using modern sensors, controls, and software to achieve a reduction in capital expense (CAPEX) for the systems, radically improved safety practices, and production of new product forms with higher purity. In addition, reduction in the size of the process provided recovery and recycling of reagents to decrease operating expense (OPEX). Closed loop operations of reagents and reduction of volumes of reagents also produced an environmentally neutral process with minimal gaseous emissions, no liquid wastes, and no hazardous waste. The innovation described through modernization of a process used since the 1930’s for industrial production of nickel and based on Mond chemistry from the 1890s makes the process available at a reduced scale and competitive costs. A smaller footprint and drop in CAPEX also increases the number of potential applications and makes the process practical for smaller mining and concentration applications with obvious savings in labor, logistics, and environmental compliance. The same design options can be applied to many critical materials where high purity production is desired. This will be especially important to Rare Earth Element refining where the Mond principles for separation can be applied to low value concentrates and ores and extensive serial extraction time and process steps can be avoided.