High efficiency separation of bastnaesite (REFCO3) and monazite (REPO4) in mixed rare earth concentrate by heating under N2 and leaching with HCl/AlCl3

Bayan Obo mixed rare earth (RE) concentrate is one of the most significant rare earth mineral resources worldwide. However, the concentrated sulfuric acid roasting method, which is commonly used to treat ores, generates pollutants such as waste gas, wastewater, and leach residue, resulting in the squandering of the associated resources. This paper introduces a green process involving selective mineral phase transformation (MPT) by heating, followed by leaching to separate bastnaesite and monazite in a mixed RE concentrate to facilitate their subsequent decomposition or extraction. The effects of the MPT conditions on rare earth extraction were investigated. During the MPT process, bastnasite decomposed into REOF, which is more easily leached, whereas monazite remained unchanged. Under suitable conditions, the leaching efficiency of REOF reached 93.7%, while that of monazite (REPO₄) was only 3.2%. Furthermore, the content of monazite in the leach residue was 91.2%. Compared to the mixed RE concentrate, numerous cracks and pores were generated on the surface and inside the MPT products. Furthermore, the total pore volume and specific surface area significantly increased, which made the reaction between the MPT products and hydrochloric acid more efficient. Thus, the MPT process facilitated the leaching of bastnasite and its separation from monazite.