The Caustic Crack Route for Processing Concentrate from the Avalon Nechalacho Deposit

The mineralogy of the Avalon Nechalacho deposit is complex with significant fractions of HREEs, Zr, and Nb found in refractory minerals such as zircon and fergusonite. Sulphuric acid baking followed by water leaching can be used to extract REEs from flotation concentrates, but acid baking does not completely "crack" the zircon and fergusonite, so the extractions of Zr, Nb, and HREEs are not high. An alternative flowsheet has been developed that is able to obtain significantly improved extractions of HREEs, Zr, and Nb from flotation concentrates or acid bake residues. This is accomplished by cracking the zircon and fergusonite minerals with caustic soda at high temperatures, followed by water washing to recover excess caustic soda and soluble sodium silicates and phosphates. REEs, Zr, and Nb in the solid residue can then be solubilized with HCl or H2SO4. This paper highlights some of the findings from an extensive laboratory program and discusses several flowsheet implications.