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Separation of Yttrium From Pregnant Leach Solution of Rare Earth Ore Using Hydrometallurgy 

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Project Summary

Our consulting engineering firm was engaged by a Canadian company seeking to improve the efficiency of its rare earth element (REE) recovery process from recycled REE ores. The client’s pregnant leach solution (PLS) contained a high concentration of Yttrium (Y), which significantly increased reagent consumption during solvent extraction. The goal was to selectively remove yttrium prior to solvent extraction without co-precipitating high-value REEs such as Neodymium (Nd), Praseodymium (Pr), Terbium (Tb), and Dysprosium (Dy). Our role encompassed process development, flowsheet design, preliminary technoeconomic analysis, and ongoing technical advisory. 

Challenge

The presence of Yttrium in high concentrations within the PLS posed a major bottleneck in downstream processing. Yttrium competes with critical REEs during solvent extraction, consuming large volumes of extractant and lowering process efficiency. The challenge was to develop a precipitation-based method to selectively remove Yttrium while maintaining high recovery and purity of the remaining REEs. This required precise control of chemical conditions to avoid co-precipitation and ensure compatibility with existing flowsheets.

Solution

We delivered a practical and effective solution tailored to the client’s operating context:
Selective Precipitation Development:

Designed a chemical precipitation process to remove yttrium with high selectivity, minimizing losses of Nd, Pr, Tb, and Dy. 

Process Flowsheet:

Developed a comprehensive flowsheet incorporating the precipitation stage and its integration with upstream leaching and downstream solvent extraction. 

Preliminary Technoeconomic Analysis:

Conducted a preliminary TEA to evaluate the cost implications of the new unit operation, including reagent use, operational expenses, and potential savings in solvent extraction. 

Advisory
Support:

Provided continuous consulting throughout the development process, including experimental design guidance and process optimization strategies. 

Key Results

Increased Solvent Efficiency:

Significant reduction in extractant consumption during solvent extraction due to effective Yttrium removal.

Maintained REE Purity and Yield:

Selective precipitation achieved low co-precipitation losses, preserving the economic value of the target REEs.

Integrated Process Design:

The new unit operation was successfully incorporated into the client's existing process framework with minimal disruption.

Business Impact

Our contributions enabled the client to:

  • Improve overall process efficiency and reduce operating costs through targeted removal of Yttrium. 
  • Enhance the value of their recycled REE streams by maximizing recovery of critical rare earths. 
  • Strengthen the technical foundation for future scale-up and commercialization efforts. 

This case exemplifies our expertise in developing targeted, cost-effective separation strategies that support resource optimization in complex hydrometallurgical systems. 

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