Closed Lanthanide Processing System for Rare Earth Oxide Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for extracting and processing lanthanides are inefficient and environmentally risky due to the use of open chemical processes, leading to contamination and low recovery rates, with existing closed systems being basic and batch-oriented rather than continuous.
Innovation Solution
A completely closed and continuous system for processing lanthanides that includes reception and conditioning, desorption with a countercurrent stream of desorbent, separation of fine solids, precipitation of secondary minerals and rare earth carbonates, and calcination to produce rare earth oxides, with a secondary process for further processing residual minerals and recirculation of desorbent solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If in situ desorption or heap leaching methods are used, then extraction cost is reduced, but environmental contamination and low recovery rates occur
Solution Approach 1:
The patent implements a completely closed processing system where all chemical operations occur in sealed vessels and pipelines. The system recirculates desorbent solutions and captures emissions, creating an inert environmental boundary that prevents contamination of the surrounding area while maintaining efficient extraction processes.
Solution Approach 2:
The system incorporates continuous monitoring and recirculation of desorbent solutions, where spent solutions are recovered, regenerated, and fed back into the extraction process. This feedback loop maximizes recovery rates by repeatedly extracting remaining minerals while minimizing waste discharge.
2Ease of manufacture
If in situ desorption is used, then extraction cost is reduced, but groundwater contamination occurs
Solution Approach 1:
The patent replaces open in situ desorption with a closed-system approach where all desorption operations occur in sealed vessels. The system uses enclosed pipelines for solution transport and incorporates containment structures that prevent any contact between processing fluids and groundwater, eliminating the contamination pathway while maintaining cost-effectiveness.
3Object-affected harmful factors
If heap leaching is used, then groundwater contamination is avoided, but large surface area and topography changes are required
Solution Approach 1:
The patent extracts the mineral processing operation from the natural environment by bringing all extraction activities into closed, contained vessels and facilities. This concentrates the process footprint, eliminating the need for large heap structures and associated topography changes while maintaining groundwater protection through the closed system design.
4Device complexity
If conventional batch processing is used, then system complexity is reduced, but productivity and recovery rates are low
Solution Approach 1:
The patent implements continuous processing where ores are constantly fed through the extraction system, and desorbent solutions continuously circulate through multiple extraction stages. This continuous operation, combined with counter-current flow arrangements, maximizes contact time and extraction efficiency, achieving high recovery rates while the modular design keeps system complexity manageable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances extraction efficiency, reduces environmental impact, and minimizes waste by allowing recirculation of desorbent solutions and reducing equipment size, while achieving higher recovery rates and safer operations.
Implementation Method 1
desorption of valuable product through a series of mixing and reaction stages, wherein the raw material is contacted in countercurrent with a stream of a desorbent agent
Implementation Method 2
The method comprises the following steps: a) reception and conditioning of the raw material; b) desorption of valuable product through a series of mixing and reaction stages
Implementation Method 3
c) separation of fine solids
Implementation Method 4
d) precipitation of secondary minerals through the use of a first reactive solution
Implementation Method 5
e) precipitation of rare earth carbonates through the use of a second reactive solution
Implementation Method 6
f) drying and calcination of the carbonates to obtain rare earth oxides
Data Source
AI summary
The invention relates to a system and a method for the processing of minerals containing the lanthanide series and the production of rare earth oxides, which allow a completely closed and continuous treatment of the different materials and desorbent agents involved in the process, thus improving the efficiency in the extraction and avoiding environmental risks associated. The method comprising the steps of: reception and conditioning of the raw material; desorption of valuable product through a plurality of mixing and reaction stages in which the raw material is contacted in countercurrent with a stream of desorbent solution; separation of fine solids; precipitation of secondary minerals through the use of a first reactive solution; precipitation of rare earth carbonates through the use of a second reactive solution; and drying and roasting of the rare earth carbonates to obtain rare earth oxides; wherein the method further comprises a secondary process that allows further processing of the residual mineral, and a dewatering and washing step wherein the residual mineral from the desorption step is washed and a lanthanide-containing liquid is recovered.