Integrated Coal Fly Ash-to-Critical Minerals Process
Technology
Stage 1
Stage 2
01
Carbon Recovery & Ash Upgrading
The first processing stage removes unburned carbon from coal fly ash using flotation technology, producing immediate commercial outputs while preparing the material stream for rare earth recovery.
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Ash slurry pumping and conditioning
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Hydrocyclone classification
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Reagent conditioning for flotation
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Flotation separation of carbon fraction
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Thickening and filtration of outputs
Outputs: Carbon fuel concentrate · Decarbonized mineral ash
02
Rare Earth Element Recovery
After carbon removal, rare earth elements are concentrated in the residual mineral fraction. PanoraX applies selective pre-concentration followed by hydrometallurgical extraction to isolate high-purity rare earth carbonates.
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Mineral pre-concentration
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Acid leaching of the mineral matrix
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Solution purification and clarification
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Solvent extraction separation
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Precipitation of rare earth carbonates
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Drying and packaging of final concentrate
Output: Rare earth element concentrate
Water & Resource Efficiency: The process operates with a closed-loop water system. The majority of process water is recycled back to the head of the circuit, minimizing freshwater consumption and environmental discharge at every operating site.
A Proven Technology Foundation
PanoraX Minerals pursues targeted partnerships to accelerate deployment and de-risk capital formation.
Processing facilities are designed for direct integration with active or legacy ash ponds, minimizing logistics costs and enabling on-site remediation at partner locations.
Emissions Reduction
Incorporating processed fly ash into cement production delivers measurable, quantifiable CO₂ reductions relative to conventional Portland cement manufacturing. These reductions are verifiable under established lifecycle assessment methodologies and qualify for carbon credit frameworks.
Environmental Remediation
Active processing of ash ponds reduces long-term environmental risks associated with coal ash storage, including leachate contamination, structural failure, and regulatory liability — supporting site closure and land reuse objectives for utility partners.
Products
Carbon Fuel Concentrate
Recovered carbon from fly ash is reused as a supplemental fuel in coal power plants, with a heating value of approximately 15–18 MJ/kg, reduced ash content, and stable combustion properties. This product allows utilities to recover energy value from previously wasted residual material.
Low-Carbon Cement Feedstock
Decarbonized fly ash is a critical raw material enabling significant CO₂ reductions in cement production. A 20% substitution of processed ash can reduce emissions by approximately 17%, while ultra-low carbon ash formulations can achieve reductions of up to 20% — qualifying for green procurement and sustainability-linked financing programs.
Rare Earth Element Concentrate
PanoraX recovers a suite of critical rare earth elements — including lanthanum, cerium, neodymium, praseodymium, and dysprosium — essential components in electric vehicle motors, wind turbines, advanced electronics, and defense systems. This concentrate establishes a new domestic supply chain for strategic materials.
Carbon Fuel
Heating Value
Per kilogram of recovered carbon concentrate
18MJ
Max CO₂
Reduction
In cement production using ultra-low carbon ash
20%
Rare Earth
Concentration
Typical upper range in North American fly ash deposits
600PPM