High-Pulp-Density Rare Earth Cracking for Lower-Cost Extraction
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Solution Overview
Problem
Current rare earth element extraction processes are costly and inefficient, requiring multiple steps and high energy consumption, with conventional acid baking and water leaching methods failing to optimize metallurgical performance.
Innovation Solution
A high pulp density cracking process involving grinding, mixing with strong acid and water to form a slurry or mud, followed by cracking at elevated temperatures and leaching with an aqueous solution to extract rare earth elements, optimizing pulp density and reaction conditions to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional acid baking and water leaching methods are used, then the extraction process is established, but capital and operating costs are high and metallurgical performance is not optimized
Solution Approach 1:
The patent applies parameter changes by modifying the pulp density parameter to high levels (solid-to-liquid ratio of at least 33%) and adjusting temperature parameters (30°C to 300°C range) during the cracking step. These parameter changes enable a single-step process that achieves improved metallurgical performance while reducing capital and operating costs compared to conventional multi-step acid baking and water leaching methods
Solution Approach 2:
The patent merges the cracking and leaching operations into a single integrated high pulp density cracking step. By combining these traditionally separate processes into one operation using high solid-to-liquid ratios, the patent eliminates the need for separate acid baking and water leaching steps, thereby reducing capital costs and simplifying the overall extraction process while maintaining reliable metallurgical performance
2Reliability
If conventional extraction processes are used, then the extraction is completed, but the process requires multiple steps and takes longer time
Solution Approach 1:
The patent combines multiple extraction steps into a single high pulp density cracking operation. By integrating cracking and leaching into one step using high solid-to-liquid ratios, the process achieves complete extraction in a single operation rather than requiring sequential acid baking followed by water leaching, thereby significantly improving processing speed and productivity
Solution Approach 2:
The patent maintains continuous useful action by conducting the cracking step at high pulp density where the concentrated acid and solid ore particles remain in intimate contact throughout the reaction period (30 minutes to 6 hours). This continuous interaction ensures complete extraction occurs during the single cracking step without requiring additional leaching time, thereby improving overall processing efficiency
3Reliability
If conventional acid baking and water leaching are used, then the process is established, but energy consumption is high
Solution Approach 1:
The patent applies parameter changes by conducting the cracking step at relatively low temperatures (30°C to 300°C, with many embodiments using ambient or mildly elevated temperatures) compared to conventional acid baking which requires high temperatures. This temperature parameter change significantly reduces energy consumption while the high pulp density ensures extraction effectiveness is maintained through increased reactant contact
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
The process significantly reduces capital and operating costs while maintaining or improving metallurgical performance, achieving higher rare earth element recoveries in shorter times compared to conventional methods.
Implementation Method 1
combining the ground ore with a strong acid in an amount from 100 g-1000 g of the strong acid per 1000 g of the ground ore to form a slurry or a mud; cracking the slurry or mud at a reaction temperature or over a range of reaction temperatures of from about 30° C. to less than 100° C. for a period of time from about 30 minutes to about 6 hours in a reactor
Implementation Method 2
leaching the product of step (d) with an aqueous leaching solution to obtain a leachate comprising the one or more rare earth element
Data Source
AI summary
The present application provides a process and system for extraction of rare earth elements from a solid feed that employs a high solid to liquid pulp density during cracking. In particular, the present application provides a high pulp density cracking water leaching process for extracting rare earth elements, which comprises: combining a ground solid feed with a strong acid and water to form a slurry or mud having a solid to liquid pulp density of at least 33%; cracking the slurry or mud in a reactor, with or without agitation; and leaching the slurry with an aqueous leaching solution to obtain a leachate comprising the rare earth elements. Also provided is a system for extraction of rare earth elements, which includes a grinding and/or milling device, a cracking reactor and a leaching device C configured to perform the high pulp density cracking water leaching process.