Rare earth extraction and separation from mixed bastnaesite-monazite concentrate by stepwise carbochlorination-chemical vapor transport

A stepwise carbochlorination-chemical vapor transport (SC-CVT) process is proposed for the rare earth extraction and separation from a mixed bastnaesite-monazite concentrate based on thermodynamic and kinetic analysis using carbon as reductant, chlorine gas as chlorination agent, SiCl₄ as defluorination agent, and AlCl₃ as vapor complex former. Between 500 °C and 800 °C, apparent activation energy of the carbochlorination within 2 hours changed from 22 to 16 kJ/mol roughly for the initial half hour and final 1 hour, respectively, in the absence of SiCl₄; but these values reduced to 15 and 2.1 kJ/mole under 2 kPa of SiCl₄ gas. The rare earth chloride yield for 2 hours was 56 to 88 mol pct in the absence of SiCl₄ and 92 to 99 mol pct in the presence of SiCl₄; but carbochlorination at above 1000 °C yielded a large amount of acid-insoluble residue. This, together with the negligible equilibrium vapor pressure of ThCl₄ at below 600 °C, suggests that carbochlorination of the mixed concentrate at temperatures as low as 500 °C in the (Cl₂ + SiCl₄) atmosphere is suitable for rare earth extraction and thorium-free volatile by-product release, which is different from the conventional Goldschmidt process at 1000 °C to 1200 °C. The CVT reaction of the carbochlorination product was performed at 800 °C for 0.5 hours in the (Cl₂ + SiCl₄ + AlCl₃) atmosphere and then at 1000 °C for 6 hours in the (Cl₂ + AlCl₃) atmosphere along different temperature gradients, leading to complete thorium removal and efficient rare earth separation, respectively. Their combination allows an efficient and environmentally conscious extraction and separation of rare earth elements from the mixed concentrate.