Maboumine Project: A Hydrometallurgical Process for the Recovery of Rare Earth Elements from a Polymetallic Ore Deposit in Gabon

"Mabounié is a polymetallic deposit in Gabon containing niobium (1.2%), tantalum (0.03%), rare earth elements (REE) (1.4%) and uranium (0.03%) that are mostly carried by Pyrochlore minerals. Classical route for niobium recovery is a pyrometallurgical process that consists in pyrochlore flotation, dephosphorization of the niobium concentrate and aluminothermy to obtain ferro-niobium. Pyrochlore concentrates can also be treated by a hydrometallurgical process with a mixture of sulfuric and hydrofluoric acid leaching followed by solvent extraction to separate niobium and tantalum. However, the first process does not allow recovering REE and the second one is not environmentally friendly because of the use of HF.ERAMET is looking for new opportunities on strategic metals market and has recently developed a hydrometallurgical process for the recovery of all these metals based on a sulfuric acid treatment of the ore. After solubilisation of the valuable elements, niobium / tantalum are precipitated as a concentrate (12% w/w Nb and 0.3% w/w Ta) while REE (2.7 g L-1) and uranium (90 mg L-1) remain in solution. Nearly 90% of REE are recovered from the solution by conventional REE double salt precipitation [NaREE(SO4)2.xH2O) method but some REE still remain in solution as this method does not allow to quantitatively recover medium (Sm, Eu, Gd, Tb, Dy) and heavy (Ho, Er, Tm, Yb, Lu, Y) rare earth elements. From the different process routes studied (solvent extraction, precipitation, ionic exchange etc.), an innovative method has been developed and patented to recover REE residual concentration in solution. This is based on an aluminum removal step followed by precipitation of REE as REE phosphate concentrate (REEPO4) by phosphate addition into solution. The phosphate concentrate is then purified according to the conventional monazite treatment, i.e. caustic conversion and REE solubilisation in acidic media."