The Effect of Iron- and Calcium-Rich Waste Rock's Acid Baking Conditions on the Rare-Earth Extraction

The work investigates the effect of sulfuric acid baking on rare earth element (REE) extraction from two waste rock samples from a phosphate mine. The role of different mineralogical assemblages and the degree of alteration (i.e., weathering), and the behavior of the main impurities-iron, phosphorus, and calcium-on REE extraction are emphasized. For both samples, the sulfuric acid baking at 25 degrees C, during 15 min, H2SO4:sample (w/w) mass ratio of 0.45:1 is the best condition for achieving the selective leaching of REE. For the iron rich-sample, the increase in temperature reduces REE extraction and increases iron dissolution. The corresponding sulfuric acid consumed by goethite (alpha-FeOOH) from 25 degrees C to 160 degrees C acid baking is ten times higher than that required for the monazite (REEPO4) reaction. Conversely, higher REE and lower iron extraction are observed by increasing (sulfuric acid/sample) mass ratio (0.95:1). Due to the high sulfuric concentration during dissolution, a local saturation zone close to the dissolution front caused the precipitation of iron oxyhydroxides. The calcium-rich sample shows lower REE extraction by leaching (63% maximum) mainly due to the entrapment of REE-bearing minerals by a gypsum layer, and lanthanide's uptake by calcium sulfate compounds formed during leaching. The results were discussed with the help of a detailed characterization of the residues.