Bastnaesite Beneficiation by Froth Flotation and Gravity Separation

Rare earth elements are in high demand in the USA. Bastnaesite, a rare earth fluorocarbonate containing primarily cerium and lanthanum, is one of the most abundant sources of rare earths in the USA. This research was completed using the ore from Mountain Pass, which is the largest rare earth mine in the USA. This research, resulting in a current patent application, was done to find a way to combine flotation with novel collectors and gravity separation techniques to reach an enhanced grade and recovery of rare earth elements while rejecting the gangue minerals, calcite, barite, and silicate minerals. These minerals, particularly calcite, an acid consumer, are well known to be difficult to separate in conventional flotation of bastnaesite ore. Four collectors were examined. They were N,2-dihydroxybenzamide, N-hydroxycyclohexanecarboxamide, N,3- dihydroxy-2-naphthamide, and N-hydroxyoleamide. Through this analysis, it was determined that, to obtain the desired results, flotation would be the rougher stage and gravity separation would be utilized as the cleaner stage. Bench scale flotation tests were conducted on the run of mine ore using conditions that were determined using a previously utilized Stat Ease model for testing and statistical optimization in design of experimentation. The bench tests that produced the most desirable results were then scaled up to a 10 kg float test. A concentrate from this test showed a rare earth oxide grade of 44%, while rejecting 91% of the calcite. This concentrate was used for gravity separation. Through gravity separation, it was found that another 40% of the calcite could be rejected with a final rare earth oxide grade of 47% in the concentrate.