Abstract
Monazite ore processing is a complicated matrix which is mainly attributed to the presence of high phosphate (25% of P2O5) and sulfate concentration, hence, complicate the extraction and separation of REEs and other elements. Therefore, this work developed technical systematic studies for monazite processing using alkali solution, resulting in the removal and recovery of phosphate as a valuable product. Moreover, solvent extraction technique was used for selective separation of Th(IV) followed by the chemical precipitation of REEs. According to the obtained results, it could be stated that the early washing step is more efficient for removal of 92.8% of P2O5 hence; the separation of REEs from the matrix becomes more achievable. The subsequent extraction process of thorium (Th) revealed that secondary amine could be selectively and efficiently used for separation of Th and Fe with 100 and 98% efficiency respectively from U and REEs. In the residual aqueous solution, REEs were quantitatively precipitated as REEs-oxalate then separated from U.
Introduction
With their unique applications in numerous fields, the demand for rare earth elements (REEs) has increased significantly [1], driving the development of new processes to recover rare earths from a variety of new resources [2, 3]. Among a large number of rare earth minerals, only three are mainly used for rare earth production, namely bastnasite with the composition of (RE)(CO3)F, monazite of (RE)PO4 and xenotime of YPO4 [4–6]. Monazite is a rare earth phosphate also containing thorium and uranium as associated metals [7, 8]. Its structural group consists of arsenate, phosphate and silicate[9, 10].
Several technological methods are used for industrial processing of monazite. Commercially, these methods include the acid leaching in sulfuric or alkaline leaching in sodium hydroxide. In acid digestion step, monazite is treated with 98% H2SO4 at 0–230°C. The sulfate (SO42–) ion of H2SO4 acts as a ligand which reacts with REs as in Equation 1.
But the use of acids results in loss of phosphate as H3PO4. Thus, the decomposition of RE phosphates with hot, concentrated alkali was found to be suitable as tri-sodium phosphate was recovered as a by-product, which can be used as a fertilizer as illustrated in Equation 2 [11].
During the decomposition by strong alkali such as sodium hydroxide, the REEs in the forms of insoluble phosphates in monazite are transformed into the rare earth hydroxides. The rare earth hydroxides obtained from the alkaline processing can be easily dissolved in acid after removal from supernatant solution of alkaline phosphates [12].
Numerous techniques are available for the separation and recovery of REEs such as chemical precipitation, ion exchange, solvent extraction and adsorption [3–15]. Among these, solvent extraction (SX) method has wide range of application in hydrometallurgical separation process owing to its great potential on high selectivity, effective separation and high metal enrichment [16]. In solvent extraction systems, phosphates [7–19], amines [20] and carboxylic acids [21, 22] are usually studied.
Monazite contains 0.2–0.4% uranium as U3O8 and 4.5–9.5% thorium as ThO2, depending on the region of origin/occurrence [23]. In Egypt, monazite is among the economic minerals found in the Egyptian black sands which are concentrated along the beach of the Nile Delta. Egyptian monazite (purity 97%) has been analyzed and was found to assay 5.9% ThO2, 0.44% U3O8, 26.55% Ce2O3, and 34.35% other rare earths (RE2O3) [24]. Monazite ore processing is a complicated matrix which is mainly attributed to the presence of high phosphate (25% of P2O5) and sulfate concentration, hence, complicate the extraction and separation of REEs and other elements. Therefore, this work developed technical systematic studies for monazite processing using alkali solution, resulting in the removal and recovery of phosphate as a valuable product. Moreover, solvent extraction technique was used for selective extraction and separation of Th(IV) followed by the chemical precipitation of REEs.
Experimental
Chemicals and reagents
The monazite used in this work was obtained from Nuclear Materials Authority, Egypt. All chemicals and reagents used were analytical reagent grade and their solutions were prepared with distilled water. All REEs standards were obtained from Sigma Aldrich (99.9%).
Instruments
Optical emission inductively coupled plasma (ICP-OES, Hudson, New Hampshire, 03051, U.S.A) was used for measurements and detection of various elements concentration. The chemical composition of the high grade concentrate (HGM 92%) was determined by X-ray fluorescence spectrometry using a PW-2400 spectrometer (Phillips, Netherlands).
Experimental procedure
Trials were performed for digestion of high grade monazite (HGM 92%) using alkaline technique. Representative HGM sample was subjected to XRF analysis to determine its original elemental compositions. The alkaline digestion of monazite was achieved by mixing 20 g of monazite (92%) slowly with 40% caustic soda solution then stirred for 3 h at 140°C. The mixture was then diluted with another 20% NaOH and stirred for 1 h at 105°C. Filtration was carried out (filtrate, sample no. P1), and the yellowish brown monazite cake (residue) was washed with 75 ml dist H2O at 100°C for 10 min. (4 times). Each two washing steps were collected together in one sample (samples no. P2, P3). The residue was then dried (in the oven) and the weight of the dry residue was found to be 19 g. The dry residue was divided into 3 portions (6 g each). The resulted yellowish brown cake after monazite digestion was shown in Fig. 1.

Yellowish brown cake after monazite digestion by caustic soda.
The leaching step for the 3 portions was carried out using different acids (conc. HCl, conc. HNO3, conc. H2SO4). The first portion was leached with 20 mL conc. HCl at 80°C for 1 h (3 times) giving 3 dissolved samples (C1, C2 and C3).
The second portion was leached with 20 mL conc. HNO3 at 80°C for 1 h (3 times) giving 3 dissolved samples (N1, N2 and N3). The third portion was leached with 20 mL conc. H2SO4 at 80°C for 1 h (3 times). Unfortunately, in case of sulfuric acid leaching, the whole reaction mixture was converted to refractory solid material and hence it was excluded.
The leached samples by HCl were then collected together to give the HCl leached solution with total volume of 25 mL (sample no. F1). 8 mL of this sample was diluted into 100 mL and the pH was readjusted from 0.77 to 2.5 (sample no. F2). Different portions (10 mL each) from sample no. F2 were taken and shaken individually with 10 mL of 0.2 M of different organic extractants (Octylamine, N-Methylaniline, N,N-Dimethylaniline (Fig. 2) and Tri-N-Butyl Phosphate (TBP)) for 30 min., with the phase ratio 1 : 1. All the tested extractents were dissolved individually in petroleum ether at 25°C. The aqueous phase (sample no. F3) separated from the organic phase (N-Methylaniline) was divided to 3 portions and mixed individually with different concentration of oxalic acid (2, 3 and 4%). All the above presented samples of digestion, washing, leaching and extraction were subjected to ICP analysis.

The chemical structure of the investigated amines.
Monazite digestion, washing and acids dissolution
The data for the elemental composition of the monazite sample (92% grade) are represented in Table 1.
XRF analysis for monazite sample (92%)
XRF analysis for monazite sample (92%)
In the metallurgy process, the reaction between the phosphorus and RE results in the formation of various phosphides causing pulverization of the RE-complexes [25, 26]. Therefore, it is very essential to eradicate phosphate present in the ore in order to enhance the dissolution of REEs.
During the monazite digestion, all the original phosphorus in the resultant hot slurry was converted into trisodium phosphate while rare earths and the other associated metals were converted into hydrous metal oxide cake (Yellowish brown monazite cake).
According to the digestion process, the alkaline digestion of monazite giving 2 products:
hot slurry, which contain mainly P2O5 (92.8%) and traces from Fe2O3, ThO2, La2O3, CeO2 and Nd2O3 (Table 4, washing step); hydrous metal oxide cake, which contain major Fe2O3, U, ThO2, La2O3, CeO2, Nd2O3 and Y2O3 (Table 4, HCl and HNO3 Leaching).
The solution species resulting from alkaline digestion can actually be represented according to Equations 2, 3, 4.
The washing step was repeated different times until all the trisodium phosphate and free caustic soda had been removed from the cake.
The data present in Table 2, showed the percentage element concentrations (%) after digestion, washing and leaching of monazite. These results were recalculated relative to 100 g monazite taken in consideration the volume of the sample (after digestion, washing and leaching) and the weight of monazite sample.
The percentage elements concentrations (%)
To evaluate the efficiency of each step, the data in Table 2, for the 3 different stages; washing (P1, P2, P3), leaching with HCl (C1, C2, C3) and leaching with HNO3 (N1, N2, N3) were collected and presented in Table 3.
Elements concentration by % (collected stages)
The efficiency % of the each metal relative to its original concentration (previously shown in Table 1) were calculated after conversion these metal ions into the corresponding metal oxide to be compatible with the compound formula in the XRF analysis. According to the results illustrated in Table 4, it could be stated that, washing step is more efficient for removal of 92.8% of P2O5. Therefore, it could be easy to separate the phosphate species from the complicated monazite matrix, hence; the separation of Th and REEs from the matrix becomes more achievable. Moreover HCl leaching step is more efficient rather than HNO3. The solution species resulting from extraction with HCl can be represented according to Equations 5, 6, 7.
Removal efficiency (%) relative to XRF analysis
Despite the high leaching efficiency of HCl, it could not separate REEs from the other co-existing cations such as U, Th and Fe. Therefore, the next trials were focused on separation of REEs from the hydrochloric acid leachate.
Series of experiments were attempted to separate REEs from HCl leachate with solvent extraction technique using different basic and acidic extractants followed by precipitation of REEs. The data presented in Table 5, showed the percentage elements concentration (%) after extraction.
The percentage concentration (%) of the investigated elements [Extractant concentration is 0.2 M]
The percentage concentration (%) of the investigated elements [Extractant concentration is 0.2 M]
These results were recalculated relative to 100 gm monazite to give the percentage elements concentration (%) as shown in Table 5. The percentage extraction efficiency for each organic extractants towards the investigated metal ions was calculated relative to its original sample no. 2 (F2) as shown in Table 6.
Extraction efficiency % relative to F2 [Extractant concentration is 0.2 M]
According to Tables 5 and 6, it is clear that Octylamine as a primary amine is efficient to extract all the investigated elements, while N-Methylaniline is efficient for extraction of Fe and Th and less efficient for REEs and U. Also, N,N-Dimethylaniline is efficient for extraction of Fe, Th and U and less efficient for REEs. On the other hand, TBP is not effective for all of these investigated elements.
Based on the chemical structure of the investigated amines, Fig. 2, it could be observed that Octylamine is more basic than both of N-Methylaniline and N,N-Dimethylaniline [27], This is due to: the inductive effect (+
Also, the lone pair electrons on the N-atom in both of N-Methylaniline (C6H5NHCH3) and N,N-Dimethylaniline [C6H5N(CH3)2] are delocalized over the benzene ring by the ′R effect of ′C6H5 group. At the same time (C6H5N(CH3)2) is more basic than (C6H5NHCH3) due to the presence of two electron-donating ′CH3 groups in [C6H5N(CH3)2].
This explains why aliphatic amines are stronger bases than aromatic amines. Hence, the order of increasing the basicity of the given amines is given as follows:
C8H17NH2 >C6H5N(CH3)2 >C6H5NHCH3
Moreover, it is known that the higher the basic strength, the lower is the pK b values, where the pK b values increase in the order:
C6H5NHCH3 (pK b is 9.3)>C6H5N(CH3)2 (pK b is 8.92)>C8H17NH2 (pK b is 3.35)
The obtained results are in a good agreement with many previously published results. According to Kim et al. [28], zero percent extraction was observed for all rare-earths at all pH values studied using 1 mol/L Alamine 336 [tertiary amine, N,N-Dioctyl-1-Octanamine (C24H51N)] or Aliquat 336 [quaternary ammonium salt, Tri-Octylmonomethylammonium chloride (C25H54ClN)]. Similarly, Amaral and Morais [29], proved that Primene JM-T [primary amine, Dimethylheptadecan-1-amine (C19H41N)] can extract thorium with concentration not exceed 0.15 mol/L, in which increasing concentration of Primene JM-T causes an increase in extraction of rare earth elements, but this fact was not observed for Alamine 336 (tertiary amine) in the concentration range investigated which confirm that REEs can be extracted by primary amines not by secondary or tertiary amines.
After the solvent extraction step, the aqueous phase (sample from the leachate by HCl then mixed with the organic phase N-Methylaniline and separated to give sample no. F3) that contains U and REEs was treated with different concentration of oxalic acid to precipitate and separate REEs from U according to Equation 8. The results are shown in Table 7.
Aqueous phase concentration (mg/L) after oxalic acid precipitation
In this respect, The solubility product value of Y2(C2O4)3 is 5.1×10–30, La2(C2O4)3 is 6.0×10–30, Ce2(C2O4)3 is 4.0×10–31, Nd2(C2O4)3 is 1.3×10–31, Yb2(C2O4)3 is 9.5×10–31, thorium oxalate dihydrate (Th(C2O4)2.2H2O) is 5.01×10–25.
According to Table 7, it can be noticed that, oxalic acid is efficient for precipitation of REEs (more than 95%) leaving U soluble as U-oxalate complex [25], [The tri hydrate UO2C2O4.3H2O is obtained when oxalic acid is added to a uranyl salt solution (Equation 9).
Although uranyl oxalate is slightly soluble in water (0.45 g per 100 gm H2O at 20°C), its solubility behavior completely changed in the presence of the mineral acids such as HCl, HNO3 and H2SO4.
Finally, secondary amine (0.2 M N-Methylaniline at pH 2.5) was efficiently applied for separation of Fe and Th with 98 and 100% respectively from U and REEs, followed by precipitation of REEs as oxalate. The overall process of monazite digestion, leaching and extraction could be summarized and represented schematically as shown in Fig. 3.

Schematic flowchart for monazite digestion by caustic soda followed by acid leaching, organic extraction and precipitation.
Alkaline digestion of high grade monazite has been investigated. The results clearly demonstrate that washing step after digestion is efficient for removal of 92.8% of P2O5. HCl is preferred rather than HNO3 for the leaching of all elements from the yellowish brown monazite cake. Fe(III) and Th(IV) were separated from U and REEs using 0.2 M N-Methylaniline at pH 2.5 as a secondary amine while REEs were selectively precipitated as oxalate then separated from the soluble U-oxalate complex.
Footnotes
Acknowledgments
Authors are thankful to the Science and Technology Development Fund (STDF), Egypt, for the financial support, Grant No 5021. We would also like to acknowledge the Nuclear Materials Authority, Egypt for providing the required high grade monazite.
