Certain Central Appalachian coals, most notably the Fire Clay coal with a REY-enriched volcanic ash fall tonstein, are known to be enriched in rare earth elements. The Fire Clay tonstein has a greater contribution to the total coal + parting REY than would be inferred from its thickness, accounting for about 20%–35% of the REY in the coal + parting sequence. Underground mining, in particular, might include roof and floor rock and the within-seam partings in the mined product. Beneficiation, necessary to meet utility specifications, will remove some of the REY from the delivered product. In at least one previously published example, even though the tonstein was not present in the Fire Clay coal, the coal was enriched in REY. In this case, as well as mines that ship run-of-mine products to the utility, the shipped REY content should be virtually the same as for the mined coal. At the power plant, however, the delivered coal will be pulverized, generally accompanied by the elimination of some of the harder rock, before it is fired into the boiler. Overall, there are a wide range of variables between the geologic sample at the mine and the power plant, any or all of which could impact the concentration of REY or other critical materials in the coal combustion products.

In this study, Central Appalachian coal-derived fly ashes from two power plants were beneficiated in a pilot-scale facility in order to produce a product with a relatively consistent concentration of rare earth elements (REE). The <200-mesh final fly ash product was produced by removing the carbon- and Fe-rich particles prior to screening at 200 mesh (75 µm). The Plant D fly ash had high concentrations of CaO and SO₃, which were diminished through the two months when the ash was being beneficiated, representing a consequence of the heat, humidity, and excessive rainfall in the Kentucky summer. The high CaO and SO₃ concentrations through the early runs likely contributed to the lower REE in the <200-mesh products of those runs. Of the non-REE minor elements, Ba, V, Mn, Zn, and As showed the greatest between-run variations within the runs for each plant. The overall REE concentrations proved to be similar, both on a between-run basis for the individual fly ash sources and on a between-plant basis. Variations in fly ash quality will occur in larger-scale operations, so on-going attention to the fly ash quality and the response of the fly ash to beneficiation is necessary. Changes in the Plant D fly ash with time imply that both the freshness of the original ash and the length and conditions of its storage at the site of beneficiation could be factors in the quality and consistency of the processed fly ash.

Microalgae are a potential means of recycling CO₂ from industrial point sources. With this in mind, a novel photobioreactor (PBR) was designed and deployed at a coal-fired power plant. To ascertain the feasibility of using waste heat from the power plant to heat algae cultures during cold periods, two heat transfer models were constructed to quantify PBR cooling times. The first, which was based on tabulated data, material properties and the physical orientation of the PBR tubes, yielded a range of heat transfer coefficients of 19–64 W m⁻² K⁻¹ for the PBR at wind speeds of 1–10 m s⁻¹. The second model was based on data collected from the PBR and gave an overall heat transfer coefficient of 24.8 W m⁻² K⁻¹. Energy penalties associated with waste heat utilization were found to incur an 18%–103% increase in energy consumption, resulting in a 22%–70% reduction in CO₂ capture for the scenarios considered. A techno-economic analysis showed that the cost of heat integration equipment increased capital expenditures (CAPEX) by a factor of nine and increased biomass production costs by a factor of three. Although the scenario is thermodynamically feasible, the increase in CAPEX incurs an increase in biomass production cost that is economically untenable.

Due to the rapid development of electronic devices and their shortened lifespans, waste electrical and electronic equipment (WEEE), or E-waste, is regarded as one of the most fast-growing wastes. Among the categories of E-waste, waste printed circuit boards (WPCBs) are considered the most complex waste materials, owing to their various constitutes, such as plastics, capacitors, wiring, and metal plating. To date, a variety of processing technologies have been developed and studied. However, due to the heterogeneous nature of WPCBs, a thorough study on both material characterization and physical separation was needed to provide a better understanding in material handling, as well as to prepare a suitable feedstock prior to the downstream chemical process. In the present study, integrated size and density separations were performed to understand the liberation of contained metals, particularly Cu and Au, from the plastic substrates. The separation performance was evaluated by the elemental concentration, distribution, and enrichment ratio of valuable metals in different size and density fractions. Further, SEM-EDS on the density separation products was carried out to characterize the surface morphology, elemental mapping, and quantified elemental contents. Moreover, thermo-gravimetric properties of waste PCBs were investigated by TGA, in order to understand the effect of temperature on volatile and combustible fractions during the thermal processing.

Four suites of fly ash, all generated at the same power plant, were selected for the study of the distribution of rare earth elements (REE). The fly ashes represented two runs of single-seam/single-mine coals and two runs of run-of-mine coals representing several coal seams from several mines. Plots of the upper continental crust-normalized REE, other parameters derived from the normalization, and the principal components analysis of the derived REE parameters (including the sum of the lanthanides plus yttrium and the ratio of the light to heavy REE) all demonstrated that the relatively rare earth-rich Fire Clay coal-derived fly ashes have a different REE distribution, with a greater concentration of REE with a relative dominance of the heavy REE, than the other fly ashes. Particularly with the Fire Clay coal-derived fly ashes, there is a systematic partitioning of the overall amount and distribution of the REE in the passage from the mechanical fly ash collection through to the last row of the electrostatic precipitator hoppers.