Objective

The objective of this Statement of Need (SON) is to develop more effective and efficient technologies used in the chemical refining of critical minerals.  Proposals should address the following: 

  • Identify the critical mineral or minerals that will be refined using the proposed technology.   
  • A focus on certain minerals is preferred, including light and heavy rare earth elements, yttrium, tungsten, zirconium, scandium, molybdenum, tantalum, and niobium. Other critical minerals will be considered with the appropriate rationale provided. 
  • Explain why improved unit operation effectiveness is important to the future viability for domestic refining of this mineral.  A focus on nascent domestic refining of critical minerals is of particular interest rather than existing refining operations; however, other existing manufacturing capabilities will be considered with the appropriate rationale provided. 
  • Identify the state-of-the-art unit operation that is currently used, including the material, chemical, and energy inputs; the product throughputs; yields and purities; and the waste streams currently produced. 
  • Identify the incumbent technology and the innovative technology that is proposed, presenting potential changes to chemical, energy, product yields and purities, as well as waste streams intended to improve system lifecycle environment and efficiency. 
  • Provide the hypotheses to support how the alternative technologies will create efficiency gains with less chemical usage and/or waste. 
  • Provide theoretical rationale, literature findings, or prior work to justify the hypotheses. 
  • Identify the potential benefit in terms of reduction in use of hazardous chemicals and generation of hazardous waste. 
  • Proposed technologies should minimize or eliminate the use of TSCA-restricted chemicals and minimize use of CERCLA hazardous substances.1   
  • Proposed technologies should enable reduction or elimination of hazardous air pollutant (HAP) and volatile organic compound (VOC) emissions. 
  • Proof of concept should be sought by the end of the project; include key metrics for confirming proof of concept 
  • Outline the expected process to transition this technology to the domestic critical mineral refining industry and identify the steps that will be taken during the proposed project.   

Proposals should include a plan to conduct a preliminary Life Cycle Analysis2 (LCA) to help indicate the life cycle cost benefit associated with the proposed process relative to current processes. Proposals should establish a life cycle framework that can compare to the baseline process and mature as the technology or process advances through the development and acquisition processes. This tiered approach aims to develop and document a minimum data set at each stage of research and development that can be used to make informed decisions and streamline transition to an acquisition program. The LCA may include varying depths of data and information that can inform: the goal and scope of an analysis; the identity and quantity of relevant inputs and outputs to the system; and the estimation of life cycle impacts and costs. A preliminary LCA would help indicate the cost benefit associated with the proposed process relative to current processes. Any proposals that do not include an LCA should provide a reason for exclusion. 

Benefits

Use of alternative technologies can increase the efficiency of chemical refining unit operations. Additionally, alternative technologies can reduce the usage or toxicity of chemicals and/or reduce the amount or toxicity of waste formed.  These benefits should reduce the costs of critical mineral refining and aid in the acceptance and proliferation of domestic refining of critical minerals.   

Background

Critical minerals are identified by the United States Geological Survey.3  There are 60 critical minerals, including rare earth elements, transition metals, semimetals, other metals, and some compounds.  Some critical minerals have a significant domestic or allied supply while others do not.  Certain critical minerals are also Defense Logistics Agency strategic materials4 that are particular to critical Department of War applications.   

There are many processes used to refine critical minerals.  They are generally separated into pyrometallurgy and hydrometallurgy.  Pyrometallurgy uses high heat to extract, separate, and purify metals from ores.  This includes processes such as calcining, roasting, smelting, and refining, which are all highly energy intensive.  These processes use minimal chemical agents but produce significant gaseous emissions. Hydrometallurgy recovers metals from ores using water-based chemistry. It involves various sub-processes, including flotation, leaching, extraction, and other separation methods that utilize various hazardous chemicals.  Flotation is an industrial separation process used to concentrate valuable metals from raw ore by exploiting differences in surface hydrophobicity through surfactants and chemical modification.  Leaching involves use of strong acids to remove metals from ore with a degree of selectivity.  Solvent extraction is used to separate metal ions from others based on relative preference for the extractant phase.  Various other chemical processes are also used in mineral refining operations.  

Cost and Duration

The cost and time to meet the requirements of this SON are at the discretion of the proposer. Two options are available:  

Standard Proposals: These proposals describe a complete research effort. The proposer should incorporate the appropriate time, schedule, and cost requirements to accomplish the scope of work proposed. SERDP projects normally run from two to five years in length and vary considerably in cost consistent with the scope of the effort. It is expected that most proposals will fall into this category.  

Limited Scope Proposals: Proposers with innovative approaches to the SON that entail high technical risk or have minimal supporting data may submit a Limited Scope Proposal for funding up to $350,000 and approximately one year in duration. Such proposals may be eligible for follow-on funding if they result in a successful initial project. The objective of these proposals should be to acquire the data necessary to demonstrate proof-of-concept or reduction of risk that will lead to development of a future Standard Proposal. Proposers should submit Limited Scope Proposals in accordance with the SERDP Core Solicitation instructions and deadlines. 

Point of Contact

John La Scala, Ph.D.  

SERDP & ESTCP Program Manager 

Weapons Systems and Platforms  

Email: john.j.lascala.civ@army.mil   

References