Newswise — Boulder, Colo., USA: A fresh study in Geology assesses cobalt extraction potential from the Idaho Cobalt Belt (ICB) in east-central Idaho, through a detailed analysis of the Iron Creek deposit. The ICB houses the second largest known local cobalt resource, a crucial element in many rechargeable batteries essential for the shift to green energy. Cobalt demand is set to rise over 500% by 2050. About 70% of global cobalt mining occurs in the Democratic Republic of the Congo, where mining practices have faced criticism for human rights abuses, including unsafe working conditions, child labor, and human trafficking. The Biden administration has prioritized boosting domestic critical mineral production, utilizing the Defense Production Act in 2022 to enhance mineral development and reignite interest in the ICB.
Comprehending the mineral composition of the Iron Creek deposit is fundamental in assessing the potential cobalt and other vital mineral reserves that can be extracted from the location, as well as determining the most effective ore processing methods. Historically, cobalt mining in the ICB occurred intermittently in the 1900s, and the closure of the Blackbird Mine led to its designation as a Superfund site by the U.S. Environmental Protection Agency. In 2022, the Australian mining firm Jervois initiated mining operations at another site within the ICB. Furthermore, the Canadian company Electra Battery Materials has been conducting exploratory work at the Iron Creek deposit.
The Iron Creek site comprises metasedimentary rocks from the Apple Creek Formation, situated within the Belt-Purcell Basin in the southwest region. These rocks, which are over one billion years old, have a rich history of mining activities targeting various minerals including lead, zinc, silver, copper, cobalt, and gold. The Belt-Purcell Basin spans across the United States and Canada, encompassing a significant geological area that has been extensively explored and exploited for its mineral resources.
The potential for cobalt production at the Iron Creek site is estimated to be a minimum of 6,000 metric tons, but it could potentially yield even greater amounts. The recent study reveals that cobalt primarily exists in the form of cobaltiferous pyrite at Iron Creek. Other deposits within the ICB contain cobalt in two additional minerals: cobaltiferous arsenopyrite and cobaltite. In the case of Iron Creek pyrite, cobalt is incorporated into the crystal lattice by substituting iron, as both elements possess the same elemental charge. Elizabeth Holley, the lead author of the study and an Associate Professor of Mining Engineering at the Colorado School of Mines, explains that the cobalt is essentially bound within the pyrite structure itself. Consequently, extracting the cobalt necessitates the disruption or alteration of the pyrite structure.
The researchers also discovered inclusions of other critical minerals such as tellurium, silver, and bismuth within the pyrite. However, it is unlikely that these minerals can be economically extracted at present, given the current economic and technical limitations. Additionally, chalcopyrite present in the rocks holds the potential as a source of copper. Despite the growing interest in domestic mining, the United States currently lacks the necessary facilities for processing the ore from the Idaho Cobalt Belt into usable cobalt. Elizabeth Holley clarifies that if the United States intends to establish domestic supply chains for mining and processing critical minerals, there is a deficiency in infrastructure required for processing the cobalt derived from the Idaho Cobalt Belt.
Based on their findings, the study authors propose that the ore from Idaho should be separated and processed independently for copper and cobalt. Chalcopyrite, which is a potential source of copper, can be processed using existing copper smelting facilities within the United States. On the other hand, minerals containing cobalt would be ideally processed in an autoclave. Currently, there is an autoclave facility in Canada that could be utilized for cobalt processing, or alternatively, a new autoclave facility could be constructed in the United States. This approach would allow for the efficient extraction and processing of both copper and cobalt from the ore in a manner that aligns with existing infrastructure and potential future developments.
The research also records current worldwide cobalt mining and processing facilities and their interconnections, revealing that most of the global cobalt supply originates from the Democratic Republic of the Congo and subsequently undergoes processing in China.
While the demand for cobalt is anticipated to be substantial, there has been increasing attention and adoption of battery technologies that utilize alternative ingredients. One such example is lithium-iron-phosphate batteries, commonly known as LFPs. As technology progresses, there is a growing research emphasis on minimizing the reliance on cobalt in batteries. Elizabeth Holley remarks, "Technology is constantly evolving, and a current trending research area centers around reducing the cobalt content in batteries. It remains uncertain whether the projected quantities of cobalt will still be necessary in the future." This highlights the dynamic nature of battery development and the potential for shifting requirements in the future.
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