Vanadium has been strongly moving into focus in the last decade. Due to its chemical properties, vanadium is vital for applications in the upcoming renewable energy revolution as well as usage in special alloys. The uprising demand forces the industry to consider the exploration of less attractive sources besides vanadiferous titanomagnetite deposits, such as lead vanadate deposits. Mineral processing and metallurgical treatment of lead vanadate deposits stopped in the 1980s, although the deposits contain a noteworthy amount of the desired resource vanadium. There has been a wide variety of research activities in the first half of the last century, including density sorting and flotation to recover concentrates as well as pyro- and hydrometallurgical treatment to produce vanadium oxide. There have been ecological issues and technical restrictions in the past that made these deposits uninteresting. Meanwhile, regarding the development of mineral processing and metallurgy, there are methods and strategies to reconsider lead vanadates as a highly-potential vanadium resource. This review does not merely provide an overview of lead vanadate sources and the challenges in previous mechanical and metallurgical processing activities, but shows opportunities to ensure vanadium production out of primary sources in the future.

The renewable energy revolution calls for high-performing materials and makes metallic compounds like lithium, cobalt, nickel and vanadium more and more critical. Innovations contribute to inventions and developments like vanadium redox flow batteries for large-scale energy storage systems with numerous technological advantages. Potential shortages of vanadium and its sources will contribute to turbulence in vanadium pricing. Nowadays, main sources and production sites of vanadium are located in Russia, China and South Africa. About 85% of vanadium applications are ferroalloys and high-performance alloys, which make production and price of vanadium dependent on the iron ore market. Partial covering of a potential vanadium demand may be achieved by an exploitation of lead vanadate ore deposits as alternative vanadium source. In the present work, the processing of a lead vanadate ore, mainly containing vanadinite and descloizite was investigated. Based on ore characterizations and preliminary beneficiation tests, a flowsheet was developed to design a small-scale processing plant, including comminution, dewatering and gravity separation. Preliminary laboratory tests and samples from the small-scale processing plant show promising results for the recovery of vanadium in a lead vanadate concentrate with a grade of 12 to 16% V₂O₅ and a recovery of 68 to 75%.

This work includes a combined hydrometallurgical treatment of a eudialyte ore sample with a subsequent preparation of leaching residue using mechanical separation methods. Hydrometallurgical treatment contains dry digestion with sulphuric acid at room temperature and filtration of the obtained product. The objectives of adopting these procedures are to test a new digestion reactor in order to prevent silica gel formation from the eudialyte ore. The obtained results revealed that silica gel formation is prevented during dissolution with sulphuric acid. A high leaching efficiency of light rare earth elements (La, Ce, Nd, Y) was reached using the dry digestion process with sulphuric acid, where the starting molarity was 12 mol/L. After the filtration process, magnetic separation is studied as the main method to recover weakly magnetic minerals like amphiboles and pyroxenes from the leaching residue in the magnetic fraction and feldspars in the nonmagnetic fraction. A new combined research strategy was developed for the production of different concentrates such as the one bearing Zr, Hf, and Nb.

Very often, the production of silver causes devastating environmental issues, because of the use of toxic reagents like cyanide and mercury. Due to severe environmental damage caused by humans in the last decades, the social awareness regarding the sustainable production processes is on the rise. Terms like “sustainable” and “green” in product descriptions are becoming more and more popular and producers are forced to satisfy the rising environmental awareness of their customers. Within this work, an alternative environmental sound silver recovery process was developed for a vein type silver ore from Mina Porka, Bolivia. A foregoing characterization of the input material reveals its mineral composition. In the following mineral processing, around 92.9% silver was concentrated by separating 59.5 wt. % of non-silver minerals. Nitric acid leaching of the generated concentrate enabled a silver recovery of up to 98%. The dissolved silver was then separated via copper cementation to generate a metallic silver product of >99% purity. Summarizing all process steps, a silver yield of 87% was achieved in lab scale. A final upscaling trial was conducted to prove the process’ robustness. Within this trial, almost 4 kg of metallic silver with a purity of higher than 99.5 wt. % was produced.

Eudialyte ores from Norra Kärr (Sweden) and Kringlerne (Greenland) are considered a potential source of rare-earth elements (REE) for the development of a sustainable REE industry outside China. Magnetic separation is successfully applicated to recover eudialyte as a magnetic fraction. In the case of the Norra Kärr deposit, up to 20% of the REE and up to 40% of the Zr are lost during mineral processing in the non-magnetic fraction. Zr and REE are associated with non-magnetic minerals such as catapleiite, low- or non-magnetic eudialyte species, and both their intergrowths. Besides zirconosilicates such as catapleiite and eudialyte, the non-magnetic fraction has valuable and already-liberated minerals such as alkali feldspars and nepheline, which should not be considered as tailings. In this investigation, a possible way to recover REE bearing zirconosilicates from the non-magnetic fraction using flotation is presented. First, a low-grade eudialyte concentrate (1.8% Zr, 0.94% REE) from ground ore was obtained using magnetic separation. The non-magnetic fraction was then treated using froth flotation, and a Zr-REE bearing product (9% Zr, 1.5% REE) was obtained as froth product. For this purpose, phosphoric acid esters were used as selective collectors for zirconosilicates at a pH between 3.5 and 4.5. The reagent regime could be proposed not only to recover Zr- and REE-bearing minerals, but also simultaneously to remove Fe, Ti, and other colored impurities from the nepheline-feldspar product and to minimize the tailings volume.