【Frontiers in HaiChuan Chemical Technology】Monash University in Australia develops a process for extracting rare earth elements from fly ash

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Researchers at Monash University in Australia have developed a greener and more efficient method for extracting rare earth elements from fly ash, mine tailings, and electronic waste, which could serve as an alternative to traditional mining methods for obtaining these key minerals. 　　Fly ash is a fine powder resulting from the combustion of lignite, and it has long been considered an environmental pollutant; in Australia, millions of tons of it are stored in ash piles or landfills. Monash University’s approach aims to transform it back into a resource. 　　Australia has numerous rare earth deposits, and several mining projects are in development. However, it takes 10 to 15 years to develop new mines, which requires substantial funding and comes with environmental and social challenges. 　　Monash University’s “urban mining” method is capable of recovering all 17 rare earth elements, with a recovery rate of over 90%. These include high-value rare earth elements such as neodymium and dysprosium, which are used to produce the permanent magnets required for electric vehicles and wind turbines. Furthermore, fly ash in Victoria generally does not contain radioactive elements such as thorium or uranium, making its extraction safer and subject to fewer regulatory restrictions. 　　Monash University states that just fly ash can yield 45,000 tons of rare earth metals per year, which is more than twice Australia’s rare earth production in 2021 and accounts for nearly 30% of the world’s total rare earth production. These rare earths are sufficient to produce 15 million electric vehicles. 　　Victoria produces over 1 million tons of fly ash each year, with even more stored nationwide. Processing this fly ash can avoid the environmental impacts associated with new mining projects, while creating new value. 　　“By treating these stocks as resources rather than waste, we can make use of the materials already available while avoiding the environmental problems associated with new mining projects,” said Monash University. 　　The university has progressed from laboratory-scale tests to 30-liter systems, is designing a 100-liter semi-continuous unit, and is building a demonstration plant at Monash University. This technology has received industry funding, and the research team is working with government and industry partners to commercialize this process. 　　Monash University states that this approach can help establish a local green supply chain for rare earths, supporting domestic manufacturing, creating regional jobs, and reducing dependence on foreign supply chains, while also minimizing the waste generated by coal-fired power plants. 　　“This is not just a technological breakthrough—it is an opportunity to change the way Australia perceives its resources. Urban mining can support local manufacturing, reduce dependence on foreign supply chains, and create job opportunities for local communities. It also enables us to reduce the waste left behind by coal-fired power plants. Urban mining creates a leading opportunity for Australia in the world to establish a green rare earth supply chain domestically, while addressing the issue of legacy waste. It can create jobs in the region, support local manufacturing, and reduce our reliance on foreign supply chains.” 　　“This is a rare opportunity. “We don’t need to extract it; we just need to change our mindset,” the university said. 　　Monash University is working with industry and government partners to bring it to market. “With strong support, we can build a circular and more resilient supply chain for Australia’s future, fully leveraging the value of the materials we already have.