Leaching of rare earths from Abu Tartur (Egypt) phosphate rock with phosphoric acid

The leaching of rare earth elements (REEs) from Egyptian Abu Tartur phosphate rock using phosphoric acid has been examined and was subsequently optimized to better understand if such an approach could be industrially feasible. Preliminary experiments were performed to properly define the design of experiments. Afterward, 2⁴ full factorial design was implemented to optimize the leaching process. Optimum REEs leaching efficiency (96.7 ± 0.9%) was reached with the following conditions: phosphoric acid concentration of 30 wt.-% P₂O₅, liquid/solid ratio, mL/g, of 5:1, at 20 °C, and 120 min of leaching time. The apparent activation energy of the dissolution of REEs from phosphate rock using the phosphoric acid solution was -19.6 kJ/mol. D2EHPA was subsequently applied as an organic solvent for REEs separation from the acquired leach liquor. REEs stripping and precipitation were conducted, and finally, rare earth oxides with a purity of 88.4% were obtained. The leach liquor was further treated with concentrated sulfuric acid to recover the used phosphoric acid and produce gypsum with a purity of >95% at the same time. A flow diagram for this innovative cleaner production process was developed, and larger-scale experiments are proposed to further understand this promising approach to comprehensive phosphate rock processing.