Processes for rare earths recovery from wet-process phosphoric acid

A method for the removal of a rare earth component, or a mixture of rare earth components, and one or more minor element components or mixture of minor element components, from a wet-process phosphoric acid, and subsequently separating the rare earth components or the mixture of rare earth components from the one or more minor element components or the mixture of minor element components,

• the method comprising use of two or more continuous ion exchange systems comprising a strong cationic exchange resin, comprising:
• (a) providing a phosphoric acid solution comprising:
• (i) the rare earth components or the mixture of rare earth components and the one or more minor element components, or the mixture of minor element components,
• (ii) a solution comprising a phosphoric acid and the rare earth components or the mixture of rare earth components and the one or more minor element components or the mixture of minor element components, or
• (iii) a phos-acid feedstock comprising the rare earth components or the mixture of rare earth components and the one or more minor element components or the mixture of minor element components;
• (b) providing:
• (1) a first continuous ion exchange system comprising a strong cationic exchange resin capable of binding:
• (i) the rare earth components, or
• the mixture of rare earth components and
• (ii) the one or more minor element components or the mixture of minor element components,
• wherein the strong cationic exchange resin is in the H+ form, and
• (2) a second continuous ion exchange system comprising a strong cationic exchange resin with a specific affinity for a rare earth component, or mixture of rare earth components;
• (c) providing an acid regeneration solution comprising a strong acid;
• (d) applying the provided phosphoric acid solution of (a), to the first continuous ion exchange system comprising a strong cationic exchange resin of (b) under conditions that cause the rare earth components, or the mixture of rare earth components, and the one or more minor element components or the mixture of minor element components, to remain on the first continuous ion exchange system comprising a strong cationic exchange resin;
• (e) removing the rare earth components, or the mixture of rare earth components and the one or more minor element components or the mixture of minor element components, or eluting the rare earth components, or the mixture of rare earth components and the one or more minor element components or the mixture of minor element components, from the first continuous ion exchange system comprising a strong cationic exchange resin using the acid regeneration solution, resulting in or thereby producing an acid regeneration solution eluant containing or comprising the rare earth components, or the mixture of rare earth components, and the one or more minor element components or the mixture of minor element components;
• and
• (f) contacting the acid regeneration solution eluant comprising as eluates the rare earth components, or the mixture of rare earth components, and the one or more minor element components or the mixture of minor element components, with the second continuous ion exchange system comprising a strong cationic exchange resin with a specific affinity for a rare earth component, or mixture of rare earth components,
• wherein the second continuous ion exchange system comprising a strong cationic exchange resin binds the rare earth components, or the mixture of rare earth components, and separates the rare earth components, or the mixture of rare earth components, from the one or more minor element components or the mixture of minor element components,
• wherein the one or more minor element components or the mixture of minor element components comprise:
• iron, aluminum and/or magnesium or their respective oxides.