Rare Earth Extraction via Low-Temperature Acid Soak
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Solution Overview
Problem
The rare earth elements extraction process, particularly the acid baking method, is inefficient and costly due to the similarity in chemical properties of REE, leading to high operational costs and environmental concerns.
Innovation Solution
A process involving a long-term acid soak at temperatures below 100°C, optionally with added water and metal ions, followed by a water leach, which replaces or reduces the need for acid baking, enhancing REE solubilization and recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If acid baking at high temperature is used for REE extraction, then decomposition of ore is achieved, but energy consumption increases and equipment complexity increases
Solution Approach 1:
The patent changes the temperature parameter from high-temperature baking (>200°C) to low-temperature soaking (below 100°C), fundamentally altering the process conditions to reduce energy consumption while maintaining extraction effectiveness
Solution Approach 2:
The patent applies preliminary acid soaking treatment before leaching to pre-decompose the ore structure and convert REE to soluble forms, reducing the need for subsequent high-temperature baking and associated energy consumption
2Productivity
If acid baking is used for REE extraction, then ore decomposition is achieved, but operational costs increase
Solution Approach 1:
The patent employs extended soaking periods (at least 1 day, preferably longer) at low temperature to achieve complete decomposition and solubilization of REE, replacing the need for energy-intensive periodic baking cycles and reducing operational costs
Solution Approach 2:
The acid solution continuously acts on the ore during the soaking period, allowing the chemical reaction to proceed spontaneously at low temperature without requiring external energy input for heating, thereby reducing operational costs
3Quantity of substance
If acid baking process is used, then REE solubilization is achieved, but environmental impact increases
Solution Approach 1:
The patent changes the thermal parameters from high-temperature baking to low-temperature soaking, which reduces the formation of harmful emissions and minimizes environmental impact while maintaining effective REE recovery
4Temperature
If high-temperature baking equipment is used, then decomposition is achieved, but capital costs increase
Solution Approach 1:
The patent fundamentally changes the temperature parameter from high to low, which eliminates the need for complex high-temperature baking equipment and allows the use of simpler soaking vessels, thereby reducing capital costs
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 method increases REE recovery efficiency, reduces energy consumption, minimizes environmental impact, and lowers capital and operational costs by eliminating the need for high-temperature baking equipment and processes.
Implementation Method 1
soaking the ore with a strong acid at a temperature of less than about 100° C. for at least 1 day
Implementation Method 2
leaching the acid-soaked ore with an aqueous leaching solution to obtain a leachate comprising the rare earth elements
Data Source
AI summary
The present application provides a process and system for extraction of rare earth elements using a long-term acid soak. In particular the present application provides a process for extracting rare earth elements from an ore by: (a) soaking the ore with a strong acid at a temperature of less than about 100° C. for at least 1 day; and (b) leaching the acid-soaked ore with an aqueous leaching solution to obtain a leachate comprising the rare earth elements. Optionally, a small amount of water is added to the acid during the acid soaking step and/or an additive comprising one or more metal ions is added to the acid during the acid soaking step.