Hydrometallurgical Extraction and Separation of High-Purity Germanium from Coal Gasification Ash for Enhanced DoD Critical Materials Security

This Phase I SBIR project proposes the development and demonstration of an innovative germanium (Ge) extraction technology that utilizes process intensification techniques, specifically chemo-sonication and synergistic solvent extraction (SSX), to recover high-purity Ge from coal gasification ash (CGA). áThe core technology involves a chemo-sonication reactor system designed to enhance the leaching kinetics of Ge from CGA. This process utilizes ultrasonic waves to generate localized high-energy zones, which significantly accelerate the dissolution of Ge-bearing minerals in an acidic medium. By optimizing key parameters such as ultrasonic frequency, power density, and leaching duration, the chemo-sonication process is expected to achieve higher dissolution rates than conventional leaching methods, reducing both reagent consumption and energy requirements. Following the chemo-sonication , the leachate undergoes SSX to selectively separate Ge from co-leached impurities and other metals. The SSX process uses specially formulated extractants and modifiers that enhance Ge selectivity and recovery, targeting a final concentrate with a minimum yield of 60% Ge.In Phase I, the project will focus on extensive testing and optimization of both the chemo-sonication and SSX processes. The chemo-sonication reactor system, áwill be subjected to a series of controlled áexperiments to determine the optimal operating conditions for maximum Ge dissolution. These experiments will explore a wide range of sonication parameters, including varying frequencies, power densities, and leaching times, to establish a robust set of conditions that maximize Ge recovery. Data from these tests will be used to refine the process and improve the efficiency of Ge extraction. Simultaneously, the SSX process will be rigorously tested to optimize solvent composition, phase ratios, and contact times to achieve high selectivity and recovery of Ge. áAdditionally, scale-up studies will be conducted to evaluate the feasibility of transitioning the optimized process from the laboratory to pilot scale, assessing factors such as mixing efficiency, phase separation, and solvent regeneration.áA comprehensive techno-economic analysis will also be conducted to evaluate the cost-effectiveness and commercial viability of the proposed technology. This analysis will focus on both capital and operational expenditures, incorporating sensitivity analyses to understand the impact of key economic variables such as reagent costs, energy prices, and Ge market fluctuations .ááBy leveraging advanced process intensification methods and detailed testing protocols, this project aims to develop a scalable, cost-effective solution for domestic Ge production from CGA, aligning with national interests in resource security and sustainability. Successful completion of this Phase I project will lay the foundation for Phase II, where the technology will be further scaled up and optimized for industrial application.