Periodic Reporting for period 3 - TARANTULA (Recovery of Tungsten, Niobium and Tantalum occurring as by-products in mining and processing waste streams)
Reporting period: 2022-06-01 to 2023-11-30
The refractory metals Tungsten, Niobium and Tantalum are considered strategic commodities but the European extraction of W is quite limited, while neither Niobium nor Tantalum are extracted in Europe from primary resources.
TARANTULA’s overarching objective is to develop a suite of novel, efficient and flexible metallurgical technologies with high selectivity and recovery rates from residual materials with respect to W, Nb and Ta.
A data base, with nearly 4,000 metal sites with mining potential for W, Nb and Ta identified in Europe, has been produced and standarized to provide input to RMIS platform. Several novel technologies for the recovery of W, Ta and Nb from primary resources have been developed at lab scale. A prototype has been constructed and the most promising flowsheet produced at lab scale validated at TRL6 for the production of tungsten oxide. The obtained products (Nb/W metals, oxides and precursors) have been characterized for their commercial validation (special steel for the automotive market and others). Although, for the moment, the evaluated TARANTULA tungsten /niobium-containing products do not present the purity requirements to be commercially exploited without any further research, the general approach for the recovery of niobium/tantalum and tungsten along the project has been proved to be highly valuable and will boost the economic potential of old waste deposits, which often represent a significant source of CRMs.
TARANTULA’s overarching objective is to develop a suite of novel, efficient and flexible metallurgical technologies with high selectivity and recovery rates from residual materials with respect to W, Nb and Ta.
A data base, with nearly 4,000 metal sites with mining potential for W, Nb and Ta identified in Europe, has been produced and standarized to provide input to RMIS platform. Several novel technologies for the recovery of W, Ta and Nb from primary resources have been developed at lab scale. A prototype has been constructed and the most promising flowsheet produced at lab scale validated at TRL6 for the production of tungsten oxide. The obtained products (Nb/W metals, oxides and precursors) have been characterized for their commercial validation (special steel for the automotive market and others). Although, for the moment, the evaluated TARANTULA tungsten /niobium-containing products do not present the purity requirements to be commercially exploited without any further research, the general approach for the recovery of niobium/tantalum and tungsten along the project has been proved to be highly valuable and will boost the economic potential of old waste deposits, which often represent a significant source of CRMs.
A data base, with nearly 4,000 metal sites with mining potential for W, Nb and Ta identified in Europe, has been produced and standarized to provide input to RMIS. The regulatory framework concerning the exploration of mining residues European country wise has been investigated.
The project has established the following highly efficient and multi-purpose technologies:
Pre-processing for size reduction: Electro-fragmentation, Microwave-fragmentation, Biomimetic flotation for tungsten tailings.
Extraction and recovery of W/Nb/Ta as oxides and salts: Solvoleaching coupled to non-aqueous solvent extraction (NASX), Deep Eutectic Solvent (DES) Leaching coupled to IL extraction, Single-step microwave-assisted (fusion/ alkaline leaching) and solid/liquid extraction, Alkaline leaching coupled with solvent extraction, Novel electrodeposition processes for production of refractory metals/carbides, Solution Precursor Plasma Spraying (SPPS) to form W, Nb, Ta MO coatings in a slurry-solution.
In terms of extraction and recoveries, good yields have been obtained in general terms. And for the specific flowsheet validated at the pilot, the overall yield is 92%.
The sustainability assessment of the technologies during the R&D phase was performed and the best performing process (DES leaching + IL extraction) selected for the up-scale in the prototype. Finally, a benchmark of the process validated in the constructed pilot plant with conventional WO3 production routes was done and a set of technical recommendations were established from the lessons learned during pilot operation.
The basic engineering and modelling were developed from laboratory data. Afterwards the prototype was constructed, tested and validated after the assembly and commissioning. Validation of the produced Nb in steel was also accomplished. Additionally, desk work validation was performed for the W output. In both cases, the products/precursors (oxides) have been successfully produced although their level of impurities need to be improved with further investigations for a go-to-market strategy.
Communication, dissemination, exploitation and clustering activities were performed. A database with 555 possible stakeholders relevant to TARANTULA, a Data Management Plan, and a detailed Communication and Dissemination Plan were prepared. Market analysis report was produced to facilitate exploitation definition. Several events were organized with local communities to discuss the barriers and opportunities for the implementation of the TARANTULA technologies; for the high level multi stakeholder transition arena, SLO concept was discussed in 9 organized events. Workshops targeting industrial audiences were organized to increase visibility of TARANTULA’s processes and accelerate their future adoption from stakeholders along the value chain of W, Nb, Ta. Finally, TARANTULA contributed in clustering workshops with other projects/initiatives (co)organizing 9 Events and presenting TARANTULA in 11 external events. The Exploitation Plan report, includes the progress of innovations and definition of 10 KERs, and the creation of the Post-project Impact Follow-Up Committee (aiming to both keep the momentum with exploitation, communication and dissemination over a sufficient period of time after the project’s completion in order to fully achieve the desired project impact, and to investigate opportunities).
The project has established the following highly efficient and multi-purpose technologies:
Pre-processing for size reduction: Electro-fragmentation, Microwave-fragmentation, Biomimetic flotation for tungsten tailings.
Extraction and recovery of W/Nb/Ta as oxides and salts: Solvoleaching coupled to non-aqueous solvent extraction (NASX), Deep Eutectic Solvent (DES) Leaching coupled to IL extraction, Single-step microwave-assisted (fusion/ alkaline leaching) and solid/liquid extraction, Alkaline leaching coupled with solvent extraction, Novel electrodeposition processes for production of refractory metals/carbides, Solution Precursor Plasma Spraying (SPPS) to form W, Nb, Ta MO coatings in a slurry-solution.
In terms of extraction and recoveries, good yields have been obtained in general terms. And for the specific flowsheet validated at the pilot, the overall yield is 92%.
The sustainability assessment of the technologies during the R&D phase was performed and the best performing process (DES leaching + IL extraction) selected for the up-scale in the prototype. Finally, a benchmark of the process validated in the constructed pilot plant with conventional WO3 production routes was done and a set of technical recommendations were established from the lessons learned during pilot operation.
The basic engineering and modelling were developed from laboratory data. Afterwards the prototype was constructed, tested and validated after the assembly and commissioning. Validation of the produced Nb in steel was also accomplished. Additionally, desk work validation was performed for the W output. In both cases, the products/precursors (oxides) have been successfully produced although their level of impurities need to be improved with further investigations for a go-to-market strategy.
Communication, dissemination, exploitation and clustering activities were performed. A database with 555 possible stakeholders relevant to TARANTULA, a Data Management Plan, and a detailed Communication and Dissemination Plan were prepared. Market analysis report was produced to facilitate exploitation definition. Several events were organized with local communities to discuss the barriers and opportunities for the implementation of the TARANTULA technologies; for the high level multi stakeholder transition arena, SLO concept was discussed in 9 organized events. Workshops targeting industrial audiences were organized to increase visibility of TARANTULA’s processes and accelerate their future adoption from stakeholders along the value chain of W, Nb, Ta. Finally, TARANTULA contributed in clustering workshops with other projects/initiatives (co)organizing 9 Events and presenting TARANTULA in 11 external events. The Exploitation Plan report, includes the progress of innovations and definition of 10 KERs, and the creation of the Post-project Impact Follow-Up Committee (aiming to both keep the momentum with exploitation, communication and dissemination over a sufficient period of time after the project’s completion in order to fully achieve the desired project impact, and to investigate opportunities).
TARANTULA actively contributes to create a new infrastructure and investments to satisfy the demand for W, Nb and Ta in the EU by
• Pushing the EU to the forefront in the area of raw materials
Europe’s top scientific organisations (TEC, KUL, VITO, SINT, ULG and CHA) have developed synergetic research and innovation tasks.
• Significantly increased process selectivity, broader range and higher recovery rates of valuable raw materials
The suggested processes are highly selective and achieve greater recovery rates of the targeted metals as compared to conventional metallurgical techniques, by overcoming critical technical limitation. To illustrate this, it worths to mention the global extraction yield of 92% for the W in the production of the 99.3% WO3 rich material obtained in the prototype.
• The LCA/LCC study described in D6.3 Report on the sustainability assessment of the prototype performance and traditional routes for producing W, Nb and Ta, shows the potential viability of the developed process.
• In the longer term, improving the competitiveness of and creating added value and new jobs in raw materials processing, refining, equipment manufacturing and downstream industries
• Improving significantly the health, safety and environmental performance of the operations
The innovative technology portfolio proposed by TARANTULA, will boost the economic potential of old waste deposits, which often represent a significant source of critical raw materials. While minimising the loss of valuable content of W, Nb and Ta in mining and processing residues, TARANTULA will improve the environmental performance of the already existing European W producing sites by providing an economically feasible package of technologies to dramatically reduce the amount of waste. A
In addition to all above, the innovation potential for the research developed within TARANTULA has been assessed through the Innovation Radar methodology and has been updated with the final results achieved. KERs, which can impact differently in the medium term, that were identified during the second period of the project, have been updated.
Finally, the project TARANTULA will contribute to set up a socially inclusive strategy for bi-directional communication with the local communities where the residual materials are produced (for example the mines). Relevant activities have stimulated open discussion with local communities and other stakeholders, in view of developing and maintaining the “Social Licence to Operate” for mining and mineral waste (re)processing.
• Pushing the EU to the forefront in the area of raw materials
Europe’s top scientific organisations (TEC, KUL, VITO, SINT, ULG and CHA) have developed synergetic research and innovation tasks.
• Significantly increased process selectivity, broader range and higher recovery rates of valuable raw materials
The suggested processes are highly selective and achieve greater recovery rates of the targeted metals as compared to conventional metallurgical techniques, by overcoming critical technical limitation. To illustrate this, it worths to mention the global extraction yield of 92% for the W in the production of the 99.3% WO3 rich material obtained in the prototype.
• The LCA/LCC study described in D6.3 Report on the sustainability assessment of the prototype performance and traditional routes for producing W, Nb and Ta, shows the potential viability of the developed process.
• In the longer term, improving the competitiveness of and creating added value and new jobs in raw materials processing, refining, equipment manufacturing and downstream industries
• Improving significantly the health, safety and environmental performance of the operations
The innovative technology portfolio proposed by TARANTULA, will boost the economic potential of old waste deposits, which often represent a significant source of critical raw materials. While minimising the loss of valuable content of W, Nb and Ta in mining and processing residues, TARANTULA will improve the environmental performance of the already existing European W producing sites by providing an economically feasible package of technologies to dramatically reduce the amount of waste. A
In addition to all above, the innovation potential for the research developed within TARANTULA has been assessed through the Innovation Radar methodology and has been updated with the final results achieved. KERs, which can impact differently in the medium term, that were identified during the second period of the project, have been updated.
Finally, the project TARANTULA will contribute to set up a socially inclusive strategy for bi-directional communication with the local communities where the residual materials are produced (for example the mines). Relevant activities have stimulated open discussion with local communities and other stakeholders, in view of developing and maintaining the “Social Licence to Operate” for mining and mineral waste (re)processing.