Resource Potential of Nickel, Vanadium, Titanium, Zirconium, and Rare Earth Elements from Oil Sands Mine Waste

Secure and resilient critical mineral supply chains are increasingly important to technological advancements underpinning the energy transition, economic growth, and national security. Waste materials generated during bitumen extraction and upgrading in the Athabasca Oil Sands Region of Alberta, Canada, are potential sources of several critical minerals including V, Ni, Ti, Zr, and rare earth elements (REE). Froth treatment tailings (FTT) contain various heavy minerals including rutile, anatase, ilmenite, zircon, monazite, and xenotime with projected production containing an estimated 730,000 t/yr Ti, 609,000 t/yr Zr, and 31,600 t/yr REE through 2034. Petroleum coke contains large quantities of V and Ni primarily bound in stable porphyrin complexes, with existing stockpiles exceeding 184 Mt V and projected production comprising approximately 13,700 t/yr V and 4,840 t/yr Ni over the same period. Despite significant critical mineral contents, recovery presents challenges due to complex geochemistry and mineralogy, the presence of recalcitrant organic compounds, operational factors including geotechnical stability of tailings facilities and environmental considerations related to acid rock drainage, metal leaching, and naturally occurring radioactivity. Our assessment highlights the scale of the opportunity and underscores the need for coordinated innovation to transform oil sands wastes from environmental liabilities into critical mineral assets.