Fundamental Studies on the Extraction of Rare Earth Elements from Ion Adsorption Clays

Rare earth elements (REEs) are critically important for high-tech, renewable energy and defense industries. However, rare earth minerals (REMs) are stable compounds, requiring aggressive conditions to decompose them for their extraction and use. One exception is the ion-adsorption clays (IACs) that are mined in South China. They were formed in nature via the adsorption of the REE ions on clay minerals; therefore, they can be readily extracted into solution under mild conditions using the ion-exchange leaching process using (NH4)2SO4 as lixiviant. It also happens that IACs are the largest source of the heavy rare earth elements (HREEs) that are critical, especially for the defense industry. At present, more than 80% of the HREEs are produced commercially from the IACs mined in Southeast Asia. The objective of the present research was to study the fundamental mechanisms involved in the formation and processing of IACs using the ion-change leaching process. The first part of the project was the synthesis of IACs by contacting kaolinite samples with known concentrations of rare earth chloride (REECl3) solutions at different pHs and analyzing the synthetic IACs for XPS studies. It was found that the REE adsorption on kaolinite stays constant in acidic pHs. At pH 7 and above, adsorption density increases sharply, possibly due to the formation of REE(OH)3 and/or REE(OOH). The IACs formed under these conditions responded well to the ion-exchange leaching process by reducing the pH to below 7. In the second part of the study, the effect of iron (Fe3+) species co-adsorbing with REEs on the kaolinite surface was studied. Unlike the colloidal phases of IACs formed at pH > 7, the synthetic IACs formed in the presence of iron did not respond to the ion-exchange leaching process using (NH4)2SO4 as lixiviant. This problem has been solved by subjecting the synthetic IACs to a reducing condition to convert the Fe3+ to soluble Fe2+ species at pH < 7. The driving force for the standard exchange leaching process is the large differences between the hydration enthalpies of the Ln3+ ions that are in the range of -3,400 kJ/mole and that of the NH4+ ions (-320 kJ/mole). In the present work, alkylammonium ions (CnH2nNH4+) of varying chain lengths were used as novel lixiviants and obtained excellent results. Since these are surface active species, their concentrations in the vicinity of the clay minerals that are negatively charged would be substantially higher than in the bulk. As a result, it was possible to achieve the same level of leaching efficiencies as obtained using ammonium sulfate at approximately ten times lower reagent dosages. One of the problems associated with extracting REEs from coal-based clays is that the REE concentrations are typically in the range of 300 to 600 ppm, which makes it difficult to extract the critical materials economically using ion-exchange leaching and other processes. As a means to overcome this issue, the REE-bearing particles, including IACs and REMs, were liberated by blunging and subsequently upgraded using the hydrophobic-hydrophilic separation (HHS) process. The results showed that blunging outperformed grinding in liberating the REE-bearing particles from the clayey materials in coal. It was shown that one can improve blunging by increasing the disjoining in the thin liquid films present between clay and other minerals by controlling the double-layer (EDL) forces. These findings should enhance our understanding of the fundamental mechanisms involved in upgrading critical materials and thereby increase the economic viability of REE recovery from coal-based materials.