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Hydrometallurgy 160 (2016) 47–59

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Hydrometallurgy

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Metallurgical processes for the recovery and recycling of lanthanum from


various resources—A review
Shivendra Sinha, Abhilash ⁎, Pratima Meshram, Banshi Dhar Pandey
CSIR- National Metallurgical Laboratory, Jamshedpur, India

a r t i c l e i n f o a b s t r a c t

Article history: Various processes for the recovery of lanthanum from metallurgical and non-metallurgical resources are
Received 31 July 2015 reviewed. Lanthanum is present as a major constituent of monazite, fluorocarbonate ores, bauxite and associated
Received in revised form 17 November 2015 residues, tailings and waste liquors of rare earths, aluminium, etc. Phosphate rock, optical glasses and Ni-MH bat-
Accepted 7 December 2015
teries serve as the most recent and high concentration secondary resources of lanthanum. This review discusses
Available online 9 December 2015
the various methods of hydro-/pyro-metallurgical origin, leaching, solvent extraction, precipitation and other
Keywords:
pre-treatment options for lanthanum recovery. A separate section on recovery of lanthanum by selective
Lanthanum biosorption from various model and actual solutions is also included. The need to develop new extraction sys-
Ores tems with high lanthanum selectivity in the areas of leaching and solvent extraction are probable improvement
Secondary resources trend for the future.
Leaching © 2015 Elsevier B.V. All rights reserved.
Solvent extraction
Sorption

1. Introduction Australia (Clark, 1984; Wood, 1990a, 1990b; Chi et al., 2000a, 2000b;
Noumav, 2008). In India, Monatize is found to be association with
Lanthanum is light group rare earth element with atomic number 57 heavy minerals like ilmenite, rutile, zircon etc. in concentrations of
and atomic weight 138.9055 was discovered by Sweden chemist Carl 0.4–4.3% of total heavies in the beach and inland placer deposits of
Gustav Mosander in 1839 (Gupta and Krishnamurthy, 2004). The chem- Andhra Pradesh, Bihar, Kerala, Odisha, Tamil Nadu, West Bengal. Al-
istry of lanthanum culpably involved its formation of the ionic +3 oxi- though Bastnäsite has been reported in association with carbonatite
dation state and its higher basicity compared among 17 rare earth from Purulia distt, West Bengal and monazite has been reported from
elements which determines the extent to which cation hydrolyzes in carbonatite occurrence of Sung Valley (Meghalaya),Sevattur
aqueous solution and relative stability of salts and by exploiting this (Tamilnadu) and Samchampi (Assam), by geological survey of India
chemical feature, it can be separated by a variety of techniques like sol- (Gupta and Krishnamurthy, 2004).
vent extraction, ion exchange, fractional precipitation methods (Yu, Lanthanum is the 28th most abundant element within in the earth
1995; Chi and Xu, 1999; Vierheilig, 2014; Xie et al., 2014a, 2014b; crust (~ 32 ppm), although exits in soil (~ 26 ppm, ranging from 1 to
Weeden et al., 2015). There are no ores which contain only lanthanum 120 ppm), seawater (~ 5 ppt) and nil in atmosphere (Henderson,
as the metal component, it is found in minerals that include all the lan- 1984). Lanthanum content in unoxidized ores ranges from 20 to
thanoid elements, It mainly occurs in monazite (Ce, La, Y, Th)PO4 and 100 pm and averages 30 ppm, its direct variation in content with potas-
bastnäsite (La, Ce)FCO3 ores in appreciable quantities (Clark, 1984; sium and aluminium suggest that the lanthanum is concentrated in clay
Lottermoser, 1992; Chi and Tian, 2007). Whilst lanthanum found in intensively exits in concentrates of carbocaneous materials from host
traces in the ores of aluminium, iron, zinc and gold (Maksimovic and rocks and unoxidized ores ranged from 160 to 222 ppm (Radtke,
Panto, 1991; Frietsch and Perdahl, 1995; Xu et al., 2006; Li et al., 2009; 1936; Gupta and Krishnamurthy, 2004). The main ores from which it
Kuzmin et al., 2012; Wang et al., 2013; Ismail et al., 2014; Jaireth et al., is extracted today are monazite and bastnäsite, where lanthanum
2014). Monazite deposits in India, Malaysia, Australia, Brazil, China, makes up 25% and 38% of the minerals, respectively (Gupta and
South Africa, Sri Lanka, Thailand, and the United States, constitutes the Krishnamurthy, 2004). Allanite and cerite also contain lanthanum, but
second largest segment while bastenite deposits constitutes larger por- these ores are not mined for their lanthanum content in particular
tion of world's rare earth resources, occurs mainly in China and (Table 1). The main mining regions of the aforementioned ores making
up the world production of lanthanum exceeding over 12,500 mt/year.
⁎ Corresponding author at: CSIR, National Metallurgical Laboratory, Jamshedpur, India. The reserves of this element are thought to be in the region of 6 mt. De-
Tel.: +916572345274; fax: +916572345213. spite being one of the rare earths, lanthanum is probably one of the least
E-mail address: abhibios@gmail.com (Abhilash).
rare, occurring in a tonnage similar to that of lead and tin combined

http://dx.doi.org/10.1016/j.hydromet.2015.12.004
0304-386X/© 2015 Elsevier B.V. All rights reserved.
48 S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59

Table 1
Prevalent mineral resources of lanthanum with % La content and occurrence.

Mineral Chemical formula % La content Occurrence References

Monazite (La, Ce, Nd, Th)·PO4 25 India, China, Korea, U.S.A., Maksimovic and Panto (1991); Frietsch and Perdahl (1995);
Malaysia, Australia, Brazil Xu et al. (2006); Li et al. (2009); Kuzmin et al. (2012); Wang
South Africa, Sri Lanka, et al. (2013); Ismail et al. (2014); Jaireth et al. (2014)
Thailand
Bastnäsite — La (La, Ce)·CO3F 35 China, Australia Clark (1984); Wood (1990a, 1990b); Chi et al. (2000a, 2000b)
Fergusonite — (Ce, La, 15–24 Northern China, Ukraine Gupta and Krishnamurthy (2004)
Ce Nd)·NbO4/Ce0.6La0.3Y0.1NbO4·0.3(H2O)
Gadolinite — Ce (Ce, La, Nd, Y)2·Fe2+ Be2Si2O10 10.9–14 Norway Gupta and Krishnamurthy (2004)
Loparite (Ce, La, Na, Ca, Sr)·(Ti,Nb)·O3 11.89–13.84 U.S.A., China, Russia Chakhmouradian et al. (1999); Rofer and Kaasik (2000); Gupta
and Krishnamurthy (2004)
Parisite-Ce Ca(Ce,La)2(CO3)3F2 23.27 Russia, Brazil Zaitsev et al. (1998); Manfredi et al. (2013); Gupta and
Krishnamurthy (2004)
Yttrocerite (Ca, Ce, La, Y)·F3. xH2O 8.5–11.5 U.S.A. Gupta and Krishnamurthy (2004); Sverdrup (1968)
Allanite (Ca; La)2 (Al, Fe 2+, 0.075–7.17 India, U.S.A. Abhilash et al. (2014); Jordens et al. (2014)
Fe3+)3(SiO4)(Si2O7)O(OH)
Stavelotite-(La) La3Mn2+3Cu(Mn3+,Fe3+,Mn4+)26[Si2O7]6O30 1–2 Belgium Bernhardt et al. (2005)
Rhabdophane (Ce, La)PO4 1.8–2.0 USA Clark (1984)
Hornblende (La, Ce,Ca,Na,K)2−3(Mg,Fe2+,Fe3+,Ti,Al)5 5 USA Aide and Aide (2012)
(Si,Al)8O22(OH,F)2

(Golev et al., 2014; Goonan, 2011a, 2011b; Massari and Ruberti, 2013). and precipitation are most commonly used for lanthanum recovery. In
Lanthanum metal itself is produced by reacting lanthanum fluoride and this review, the metallurgical processes involving the intricate ways to
calcium metal, however lanthanum is only commercial in its other recover lanthanum from various resources, depending on the different
forms such as, lanthanum oxide, carbonate, chloride, fluoride, nitrate types and amounts of impurities are reviewed in consideration of
and sulphate (Gschneidner, 1980; Gschneidner et al., 2002). But, the selecting processes to recover lanthanum and incorporating the process
high price of lanthanum twinned with absence of reliable sources and for the production of the metal in bulk quantity. The selectivity of ex-
long term production has limited its commercial applications. Lantha- traction can be improved using biosorption as a technique comparative
num is a rare and expensive metal because of its scarce distribution to solvent extraction and co precipitation, which also reviewed in pres-
and difficulties associated with its extraction (Stwertka, 2012; Emsley, ent work.
2011; Gray, 2012, Binnemans et al., 2013).
There are no such commercial uses for pure lanthanum metal, but 2. Metallurgical process for the recovery and recycling of lanthanum
there are for its alloys, although its compounds have been found from various sources
wider applications in automobile catalytic convertors, ceramics, fluid
catalytic cracking, glass additives, battery alloys, phosphors, glass 2.1. Monazite
polishing industries. The properties of lanthanum led to exploitation
in many areas like Ni-MH batteries, high strength and conductive cop- Monazite is a phosphate mineral which constitutes 10–40% La along
per alloys, potentiometric chlorine gas sensors, high temperature lan- with noteworthy elements like Ce, Sm, Pr and Nd, 4–12 wt.% thorium
thanum zirconium coatings, lanthanum carbonate as a medication, and a variable amount of uranium. Monazite is found throughout the
petroleum cracking catalysts, electron dense tracer in molecular biolo- world in placer deposits, beach sands, and is also a component of the
gy, LaB6 in electron microscopes, La–Ba radiometric dating to estimate Bayan Obo deposit (Thompson, 1980). In India, the estimate of mona-
age of rocks and ores, in carbon arc lamps, additive in liquid phase zite is 10.21 million ton (mt) in 2005 which has gone up to 11.93 mt
sintering, optical glasses (~40% usage of lanthanum oxide), lanthanum in 2013. Monazite having high chemical and thermal stability, when
hexa-aluminate as thermal barrier coating for gas turbine application, attacked by strong hot acid led to transformation of phosphate ion to
lanthanum-chromite based materials for solid oxide fuel cell intercon- di-hydrogen phosphate salt and phosphoric acid, bequeathing the
nects, as alloying element in many Bi–Te, Bi–Se–Te, Mg alloys, in the ze- metal ions as water soluble salts which spiflicate the phosphate matrix
olite catalysts used in petroleum refining, in hybrid cars (Hendrick, present in the mineral (Jiang et al., 2005). Metallurgical processing of
1985; Nakai et al., 1988; Chau and Lu, 1995; Gadow and Lischka, monazite results in pulverization of rare earth complexes due to forma-
2002; Kim and Shim, 2003; Fergus, 2004; Gupta and Krishnamurthy, tion of phosphides. So, the separation of individual metal led to an es-
2004; Ji et al., 2005; Shijie et al., 2006; Tliha et al., 2007; Emsley, 2011; sential requirement to remove phosphorus from the ore, which
Dziubaniuk et al., 2012; Dejiu et al., 2013; Di Girolamo et al., 2014). Lan- decompose at higher temperature due to their high thermal stability.
thanum hydroxide is used for adsorption of phosphates from waste Decomposition of monazite studied with the influence of 10% mixture
water under the influence of chlorides, sulphates, nitrates and hydrogen of NaCl–CaCl2 was found to be 79% at roasting temperature of 750 °C
carbonate and even lanthanum phosphates monoliths act as efficient in 1 h; whereas charred coal at 1400 °C in 2 h led to 98%
perchlorate adsorbents (Sankar et al., 2014; Xie et al., 2014a, 2014b). dephosphorization efficiency, even CaO in CaO–CaCl–CaCl2 has ability
The applications of lanthanum are increasing because of its significant to decompose monazite in temperature range varying from 610 to
chemical properties over other metals. 700 °C (Shuchen et al., 2007; Wenyuan et al., 2006).
The recovery of lanthanum from its ores in substantial quantity usu- Lanthanum recovery from monazite was investigated using Na2CO3
ally involves pyrometallurgical, hydrometallurgical process or com- at temperature of 900 °C in both reducing and sulphidizing environ-
bined pyro–hydro metallurgical process. However, the energy ment, in which extraction was made from water leached residue that
consumption is higher in pyrometallurgical processes. Lanthanum selectively leaches the oxysulphide phase formed with 3.5 wt.% hydro-
found ameliorated in slags, residues, tailings and primarily produced chloric acid (Merritt, 1990). Chi et al., 2000a, 2000b reported a novel
as a by product during processing of various ores. Currently, hydromet- method for the recovery of RE containing lanthanum from weathered
allurgical processes, which mainly involve leaching, solvent extraction black earth slime using SO2 leaching followed by ammonium chloride
S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59 49

roasting resulting in a product of 92% purity at a RE recovery greater Murthy and Gupta (1980)) studied the sulfuric acid process for the re-
than 64%. Pressure leaching, electro-generated chlorine leaching and covery from monazite containing lathanum. Lanthanum is extracted
concentrated sulphuric acid leaching were performed to investigate from Moemeik Myitsone Monazite containing 13% La2O3, which was
the leaching of lanthanum and other rare earth elements, derived first digested with caustic soda where optimized condition was obtain-
from monazite concentrate at various temperature ranges (Shin et al., ed at monazite to caustic ratio of 1:2.75, digestion time of 3 h and tem-
2012). Extraction of lanthanum and other rare earths from monazite perature of 140 °C. In hydrochloric acid dissolution, 1.5 kg acid per kg
mineral was studied using NaOH fusion, withal Korean monazite monazite, dissolution time 1 h and temperature 79 °C, where nitric
dephosphorised with 50% NaOH (w/v) at 170 °C and 100 g/L pulp den- acid digestion process for time 1 h and temperature 90 °C were tested.
sity in 4 h followed by investigation of the leaching behaviour under dif- Precipitation was carried out three times using ammonium hydroxide.
ferent chemical reaction controlled model. Whilst the rare earth After 3rd precipitation, 96.0% lanthanum oxide was obtained. So the se-
hydroxide (including lanthanum) left after alkaline leaching in auto- lective precipitation process gives high purity within shorter time and
clave was dissolved in 6 N HCl at 90 °C, 60 g/L pulp density for 2 h to re- with lower cost although the solvent extraction process gives higher re-
cover 95% REMs (Panda et al., 2014). Pyro-hydrometallurgy extraction covery (Soe et al., 2008). El-Nadi (2012) deduced the synergistic separa-
of rare earths constituting lanthanum, of original and dephosphorized tion of lanthanum and neodymium derived from Egyptian monazite,
Korean monazite has been demonstrated by acid treatment. The process using organophosphorus reagents namely trioctylphosphine oxide
suggest direct leaching of both the samples at elevated temperature for (TOPO) and trialkylphosphine oxide (TRPO) in kerosene and the sug-
2 h and pulp b100 g/L resulting 36% recovery of lanthanum for 2-stage gested process for the extraction of lanthanum from monazite shown
leaching in case of original sample while in other 91.1% recovery were in Fig. 1.
achieved in single stage leaching (Kumari et al., 2013). Effect of roasting
on monazite using soda and alkali beneficiation were studied in temper- 2.2. Bastnäsite
ature range 400–900 °C, and leachability were studied in order to ascer-
tain the effect using 6 M HCl, Temp = 80 °C, pulp = 30 g/L and t = 1 h. Bastnäsite is a fluorocarbonate mineral, has the largest proven re-
Lanthanum recovery is slightly higher in case of alkali beneficiated sam- serve among all rare earth minerals in the world (Kanazawa and
ple about 97.57%, having La about 13.85 wt.% in alkali roasted sample Kamitani, 2006). Generally, a bastnäsite concentrate containing about
(Kumari et al., 2015). However in India, extraction of rare earth from 60% REO having 33% lanthanum with significant amount Ce, Nd, Pr
monazite is commercial in operation. Indian monazite is dissolved in along with Sm and Gd, or distinctly more lanthanum and less neodym-
65–70% NaOH and is processed at high temperature of 980–1190 °C. ium and heavies as compared to commercial monazite (Chi, 1989; Chen,
In the process of chlorination, monazite is mixed with charcoal and 2011). In 1980s, Mountain Pass bastnäsite was the world's major source
heated at 900 °C (Lee and Jeon, 2010; Panda et al., 2014; Shin et al., of lanthanides, later to which Chinese massive deposits of bastnäsite at
2012). Hydrochloric acid leaching of monazite was investigated by hot Bayan Obo, Inner Mongolia, provides the majority of the world's lantha-
digestion method resulting N 90% rare earth oxides (Kim et al., 2010). nides. Bayan Obo bastnäsite occurs in association with monazite, and

Fig. 1. Process flow sheet for the recovery of lathanum from monazite (Soe et al., 2008; El-Nadi, 2012).
50 S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59

unlike carbonatite bastnäsites, is relatively closer to monazite lantha- loss of rare earths, because the rare earth fluorides formed from
nide compositions (Zelikman, 1966; Gupta and Krishnamurthy, 1992; bastnasite decomposition are water-insoluble (Chi and Wang, 1996;
Kul et al., 2000; Chi et al., 2004; Gupta and Krishnamurthy, 2004; Topkaya et al., 2000; Kul et al., 2008; Zhang and Huang, 1997, Zhu and
Huang et al., 2005). Chi, 1999; Zhu et al., 2000a, 2000b; Zhu et al., 2003; Xu, 1995). Chi
The separation process for bastnäsite ores may horde operations like et al., 2004 deduced a novel process to extract rare earth from bastnasite
gravity magnetic concentration, flotation using a fatty-acid or derived from Weishan Mine having lanthanum ~ 35.06% among total
hydroxamate-based collector system (Fuerstenau et al., 1982; rare earth elements ~ 66.52%, using MgO/Ore: 0.15/1 to minimize the
Fuerstenau and Pradip, 1991; Fuerstenau and Herrera-Urbina, 1992; formation of rare earth fluoride that results in transformation of rare
Chi et al., 2001). In general, the conventional method used for extracting earth elements into their oxides at 500 °C for 1 h, followed by direct am-
lanthanum and other rare earths from the bastnäsite concentrate em- monium chloride roasting at 325 °C, 1 h and, thereby leaching using H2O
ploys sulfuric acid roasting and sodium hydroxide treatment. In China, with S/L = 1/8 at 75 °C for 2 h, followed by precipitation using oxalic
bastnäsite concentrate uses flotation to beneficiate rare earth oxides acid and conversion to oxide by roasting at 900 °C for 2 h, which results
around 66%, whilst the concentrate is then decomposed using sulphuric recovery up to RE oxides up to 95% purity and the respective flow sheet
acid roasting, followed by extracting lanthanum by leaching with hy- shown in Fig. 2. Wen-zhong et al. (2002a, 2002b) developed a process
drochloric acid, thereafter lanthanum oxide including other rare earth for the recovery of lanthanum and other rare earths from the Baotou
oxides are recovered from leachate of rare earth chlorides by precipita- rare earth concentrate by fixing the fluorine and chlorinating the RE
tion using oxalic acid, on the characteristic of their basicity difference, with ammonium chloride in the ore and the optimum conditions
followed by calcination of rare earth oxalates (Shaw, 1959; Gupta and were obtained by fixing the fluorine of the ore 80 min, with the MgO
Krishnamurthy, 1992; Chi et al., 2000a, 2000b, 2002, 2003). However, dosage m(ore)/m(MgO) = 3∶1 at 600 °C; chlorinating the fixed fluorine
the conventional methods (e.g., sulphuric acid roasting) for extracting calcine 80 min. With NH4Cl dosage m(NH4Cl)/m(ore) = 2∶1 at 500 °C,
lanthanum and other rare earths from the bastnäsite concentrate are in- the RE recovery reaches 85%. Decomposition and extraction of rare
efficient due to intensive energy requirement and lead to serious envi- earths including lanthanum ~ 31.6% among total REEs were studied
ronmental issues resulting from HF and SO2 evolution, withal chloride from bastnäsite of Baotou origin using NH4Cl, chloridizing roasting,
roasting process followed by hot water leaching causes a significant salammoniac roasting and also by carbocholoration-oxidation (Guocai

Fig. 2. Process flow sheet for the recovery of lanthanum from bastnasite concentrate (Chi et al., 2004).
S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59 51

et al., 2000; Jun et al., 2000; Li-qing et al., 2007; Shi et al., 2002; Wu et al., Bauxite containing high aluminium hydroxides, largely used for pro-
2004, 2007) have been investigated. A mixture of rare earth double sul- duction of alumina through the Bayer's process (based on digestion
fates was produced from a Turkish bastnasite-containing ~ 8.1% La by with sodium hydroxide under elevated pressure and temperature),
sulfuric acid baking results in recovery of rare earths up to 90% and since the overall refining led to production of large quantity of solid
subsequent water leaching and precipitation with 1.25 times the stoi- waste called red mud or bauxite residue (Glenister and Thornber,
chiometric amount of sodium sulphate at 50 °C for reasonable decon- 1985; Anand et al., 1996; Hind et al., 1999; Mohapatra et al., 2000;
tamination of the rare earth double sulfate salt from impurities such Agatzini-Leonardou et al., 2008; Klauber et al., 2011; Pandey, 2011;
as Th, Fe, Al and Mg was possible. The total rare earth double sulfate Raghavan et al., 2011; Rai et al., 2012). Among its complex chemical
(TREDS) content was ~90% and analysed 17.3% La with other rare earths and mineralogical characteristics, association of rare earths is reported
with traces of impurities and the respective flow sheet shown in Fig. 3 in red mud matrix (Mohapatra et al., 2000; Ochsenkühn-Petropulu
(Kul et al., 2000). et al., 1995, 2002; Zhou et al., 2008; Samal et al., 2013; Abhilash et al.,
2014). However, lanthanum content in red mud varies from ~ 30–
2.3. Bauxite and red mud 120 ppm (Mohapatra et al., 2000; Abhilash et al., 2014). In India, lantha-
num content in red mud varies from 70 to 100 ppm, which is found to
Bauxite is characterized by a particular enrichment of aluminium- be association with Al–Si matrix (Mohapatra et al., 2000; Abhilash
hydroxide minerals, such as gibbsite, boehmite and/or diaspore with et al., 2014) and the overall composition shown in Table 2.
silica, iron oxides, titania and other trace impurities like Ga, V, rare Extraction of lanthanum from red mud via hydrometallurgical route
earths and other metal. Lanthanum is found to be present ~ 50– is proven to be useful due to environmental concerns. Leaching is per-
60 ppm among the total rare earths b 2%, depending upon the source formed using H2SO4, HCl, HNO3 and using SO2 gas in diluted stream.
of bauxite (Mohapatra et al., 2000; Mohapatra et al., 2012; In general, the lixiviant for lanthanum leaching efficiency from red
Ochsenkühn-Petropulu et al., 1995, 2002; Zhou et al., 2008; Samal mud is found to be in order HNO3 N HCl N H2SO3 N H2SO4 and further
et al., 2013; Abhilash et al., 2014).Ochsenkühn-Petropulu et al., 1996 separation using solvent extraction (DEHPA, Cyanex 301, Cyanex 923,
had described the hyrometallurgical feasibility for extraction of lantha- Cyanex 272) is reported (Ochsenkühn-Petropulu et al., 1995, 2002;
num from bauxite of Jamaica origin achieving a very meagre extraction Abhilash et al., 2014). Ochsenkühn-Petropulu et al., 1996 reported the
(~11%) and co-extraction of other impurities is high which is undesir- extraction of lanthanum from red mud derived from Jamaica origin,
able. However, its concentration enriched in red mud obtained as a Greece. Lanthanum is found to be associated with rare earth mineral hy-
by-product in Bayer's treatment for alumina production. Mohapatra droxyl bastnaesite (Nd, La). However, leaching studies are carried out
et al., 2000 reported that lanthanum content enriched almost twice using aforementioned lixiviates, HNO3 and HCl have similar recoveries
(64.81 ppm to 112.46 ppm) from bauxite of Indian origin, after Bayer's although HNO3 have higher selectivity compared to HCl. Using 0.5 M
treatment. HNO3, up to 30% La recovery was achieved under the following

Fig. 3. Process flow sheet for the recovery of lanthanum double sulphate saltfrom bastnasite concentrate (Kul et al., 2000).
52 S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59

Table 2 2.4.2. Phosphoric acid


Chemical composition of Indian red mud (Abhilash Recovery of lanthanum and other rare earth oxides was developed
et al., 2014).
from aforementioned phosphoric acid from phosphate rock treatment
Constituents % using crystallization (by heating the acid in autoclave for 1 h at 200 °C
Al2O3 19.97 and it was found that crystal formed have 98% lanthanides originally
SiO2 10.23 present in the form of phosphates, while it is preferred to deflourinate
Fe2O3 37.03 acid for achieving purity),and the processing followed by leaching
TiO2 11.98
with HNO3 and partial neutralization using NH4OH for subsequent
V 0.68
La 0.007 oxalic acid precipitation, and the precipitate was calcined at 1000 °C
Ce 0.011 to yield crude oxides (Bunuş and Dumitrescu, 1992; Bunuş et al.,
Nd 0.0005 1994; Koopman et al., 1999a, 1999b; Wang et al., 2010). Wang et al.
Sc 0.005 (2011) carried a centrifugal extraction of lanthanum (up to 22.8% over
Y 0.001
total lanthanides) and other rare earths from wet phosphoric acid.
Even solvent extraction using octyl pyrophoshoric acid, TOPS 99,
Tulsion CH-96, T-PAR, synergistic mixture of DOPPA-TOPO and solid–
condition S/L: 1/50, temperature 25 °C in 24 h, as compared to other liquid extraction using solvent-impregnated resin resins was reported
lixivants of same concentration and under same condition. Maximum (Bunus, 2000; Krea and Khalaf, 2000; Kumar et al., 2010, 2011;
recovery of ~ 39% La was achieved using 3 M HNO3 for L/S ratio: 1/50, Radhika et al., 2011; Reddy et al., 2009). Habashi (1985), given a flow
pH b 0 at 25 °C in 24 h. Abhilash et al., 2014 carried out extraction of lan- sheet for the recovery of rare earths including lanthanum from wet pro-
thanum from Indian red mud where lanthanum is found to be associat- cess phosphoric acid having lanthanides about 1 g/dm−3, were shown
ed with Allanite (La) mineral. It was found to achieve 99.9% recovery in Fig. 5.
using 3 M H2SO4 at ambient temperature (~ 35 °C), S/L: 1/100 in 1 h.
Whilst separation feasibility was checked with different extractants, it 2.4.3. Phosphogypsum
has been found that Cyanex 301 had higher specificity for lanthanum Phosphogypsum is the main by-product of the production of phos-
compared to DEHPA and Cyanex 272 with 0.15 M organic concentration phoric acid and it is formed by the acidic digestion of phosphate rock
at pH 2 and shaking for 20 min. However complete purification of lan- (Koopman and Witkamp, 2000). However the lanthanide concentration
thanum extraction is under study from Indian red mud (Abhilash averages about 0.4–0.8% depending on acid digestion, where lanthanum
et al., 2014). makes 60–75% of the total lanthanides. About half of the rare earths
present in phosphogypsum can be recovered by leaching the phospho-
2.4. Phosphate rock and it by-products gypsum at ambient temperature with 0.1–0.5 M H2SO4 solution in a
solid-to-liquid ratio of 1:10 (Habashi, 1985). The leaching efficiencies
Phosphorite, phosphate rock or rock phosphate is a sedimentary can be increased by a gravity flow of the H2SO4 solution through a col-
rock which constitutes higher content of phosphate bearing minerals. umn packed with phosphogypsum (Lokshin et al., 2011). Another
The phosphate content of phosphorite is at least 15 to 20%, which is a method for enhanced H2SO4 leaching is the mechanical activation of
large enrichment over the typical sedimentary rock content of less phosphogypsum by ball-milling (Todorovsky et al., 1997).The rare
than 0.2%. However phosphate rock contains lanthanides ranges 0.1– earths containing lanthanum 78.5% among total lanthanides, can be re-
0.8% where lanthanum, cerium and neodynium make 80% of total lan- covered from the leaching solution by precipitation, for instances as so-
thanides (Habashi, 1985; Koopman and Witkamp, 2000). While in the dium rare-earth double sulphates (Lokshin and Tareeva, 2010), or by
production of elemental phosphor, slag produced called phosphogyp- solvent extraction (Habashi, 1985). However recovery of the lanthanum
sum which have lanthanides averages 0.01–0.1%, although phosphate and rare earths by solvent extraction studied with nonyl–phenyl phos-
rock of the Kola Peninsula in Russia can contain up to 1.0 wt.% of rare phoric acid (NPPA) or by selective precipitation with hydrofluoric acid
earths (El-Didamony et al., 2012; Habashi, 1985; Skorovarov et al., (Jarosiński et al., 1993). Phosphogypsum, by reaction with ammonium
1992; Zielinski et al., 1993). carbonate undergoes decomposition, so that ammonium sulphate
fertiliser and calcium carbonate are formed. The lanthanum ~ 80%
2.4.1. Phosphate rock among total lanthanides reported to be recovered by dissolution of
In acid treatment of phosphate rock, most of the rare ~70–80% of the CaCO3 in HNO3, followed by selective removal of the rare earths by sol-
rare earths (lanthanum making up to 80%) ended up in phosphogypsum vent extraction and precipitation. Although CaCO3 can be calcined to
and the rest dissolved in the leach solution, which also contains the CaO and leaching with an NH4Cl solution, results in a rare-earth rich res-
phosphoric acid. It is reported that rare earths are less incorporated in idue. When phosphate rock is leached with a HNO3 solution, all the lan-
the phosphogypsum, if leaching was performed at lower temperature thanum containing rare earths are solubilised as nitrates, thereby by
and lower acid concentration (Altschuler et al., 1967). lanthanum con- subsequent solvent extraction or precipitation (Habashi, 1985).
centration in phosphate rock (Kola USSR, Florida USSR, Khouribga
Morroco, Al-Mahameed Egypt and Lao-Kai Vietnam) ranges from 2.5. Nickel metal hydride spent batteries
21.8–31.4% among lanthanides ~ 0.8–1% (Altschuler et al., 1967;
Bliskovs et al., 1969) and the average concentration of rare earths in Nickel-metal hydride batteries (NiMH) contain rare earths (RE) and
phosphogypsum is 0.4 wt.% (Habashi, 1985; Lokshin and Tareeva, a variety of valuable metals such as nickel and cobalt. The batteries are
2010, Lokshin et al., 2011). Extraction of lanthanum and other rare in use are mainly AB or AB2 type or in mixture, where A stands for La
earths from phosphate rock had been reported using H2SO4, HCl and or rare earth alloys and B for Ni, Co and Al respectively. Nowadays, La
HNO3, although HNO3 leaching much favourable, however H2SO4 is has been substituted by Misch metal, where lanthanum making up to
commercial in extraction process due to economical reasons and it is ev- 18–28% of the total mixture (Ruetschi et al., 1995; Zhang et al., 1998).
ident that HNO3 leaching doesn't produce phosphogypsum (Aly and While there is a need of recycling of aforementioned batteries due to en-
Mohammed, 1999; Habashi, 1985; Lokshin et al., 2002a, 2002b, vironmental concerns (Reddy et al., 2005; Kao et al., 2006; Barandas
Lokshin and Tareeva, 2010). Recovery of lanthanum including other et al., 2007a, 2007b).
rare earths from phosphate rock using HNO3 leaching, HCl leaching Hydrometallurgical routes are the basis of processing spent Ni-MH
and subsequent solvent extraction using tri-butyl phosphate (TBP) batteries for recovering lanthanum and other precious metals. However,
from HNO3 leach liquor were shown in Fig. 4 respectively. leaching with HCl or H2SO4 was performed and the leachate is
S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59 53

Fig. 4. Process flow sheet for the recovery of lanthanum oxide from phosphate rock (Habashi, 1985; Aly and Mohammed, 1999).

submitted to a series or combination of different separation techniques La2O3 (Yu and Chen, 1995; Pandey, 2011).The lanthanum oxide used
(Pietrelli et al., 2002, 2005; Bertuol et al., 2009; Li et al., 2009; Provazi in lenses must be of high purity with meagre or almost free content of
et al., 2011; Gasser and Aly, 2013; Larsson et al., 2012). Pietrelli et al., other coloured transition metals and rare earth impurities (Yu and
2002 developed a process for the selective separation of lanthanum con- Chen, 1995). The addition of lanthanum oxides in optical glass is in
taining rare earth mixture using precipitation using NaOH from mixture the range of 30–40% and the total world production of optical glass is
of AB5 and AB2 NiMH batteries. The leaching performed using 2 M about 20,000 t/year. Supposing 15% optical glasses are discarded, the
H2SO4 at 20 °C for 2 h, where ~ 92.5% La including other rare earths amount of spent optical glass is around 3000 t/year. Thus, on an average,
and precious metals were extracted, and precipitation was performed lanthanum content taken to be 30%, the spent optical glass contains
using NaOH until pH b 1.5. XRD analysis revealed that five peaks of 900 t lanthanum oxide. It is estimated that upon recycling spent optical
NaLa(SO4)2.H2O confirmed with La2O3 and NaHSO4 of pure analytical glass could yield about 900 t of lanthanum oxides per year, which plays
grade reagents (Fig. 6A). A similar leaching process was applied for a spectacular role in estimated worldwide end use of lanthanum. Jiang
the mixture of NiCd and NiMH battery by Li et al. (2009), where the pre- et al. (2004, 2005) developed process is potentially apply for recycling
cipitate with ~97.8% of lanthanum and neodymium was conditioned in such secondary RE resources as spent ophthalmic glass and spent opti-
2 M HCl and subjected to separation using synthetic adsorbent (LDH + cal fibre, besides spent optical glass. Jiang et al. (2004, 2005) recovered
Cyanex 272) and the respective flow sheet is given in Fig. 6B. The LDH- lanthanum following hydrometallurgical route from a spent borosilicate
carrier is economic and efficient where the same LDH can be used for optical glass containing 43.12 wt.% La2O3. It has been found that lantha-
more than seven times (Gasser and Aly, 2013). However, extraction of num and other rare earth borosilicates are not convenient to directly
lanthanum was performed using 70% Cyanex 923, 20% TBP and 10% ker- dissolve by hydrochloric acid, so conversion to insoluble lanthanum hy-
osene (O: A: 3.5:1, 3–5 steps) from the leach liquor obtained by leaching droxide using hot concentrated optimal sodium hydroxide solution (55
with 8 M HCl, followed by stripping of loaded organic with 1 M NaNO3 wt %) at 413 K, followed by leaching using 6 M HCl as lixiviant at L/S of 8
and 1 M HCl to obtain stripped solution containing lanthanum and other and 363 K for 30 min. With the proposed process, lanthanum in the
precious metals (Larsson et al., 2012). Fernandes et al., 2013 proposed a glass was recovered as an aqueous solution of lanthanum chlorides con-
flow sheet for recovering lanthanum in form of lanthanum oxalate taining 36.5 g/L La with recovery of 99.4% La.
(La2(C2O4)3 from spent Ni-MH batteries is shown in Fig. 6C.
2.7. Ocean sea nodules
2.6. Optical spent glasses
Deep sea nodules generally contains nickel (1.25–1.5%), copper
Lanthanum-containing glass with higher high refractive index and a (1–1.4%), cobalt (0.2–0.25%) Mo (~ 0.05%), with 100 ppm La among
low dispersion, find many applications in optical lenses, for use in cam- the total REE content of ~500–1000 ppm (Acharya et al., 1999; Anand
eras, microscopes, binoculars or microscopes can contain ~ 40 wt.% of et al., 1988; Fuerstuenau and Han, 1977; Fuerstuenau and Han, 1980;
54 S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59

Fig. 5. Process flow sheet for the recovery of lanthanum oxide from wet phosphoric acid (Habashi, 1985; Wang et al., 2010).

Mishra et al., 2011; Han and Fuerstenau, 1975; Jung, 1993). There are the chemical reaction rate controlling step was determined to be
various technologies developed, using pyrometallurgical and hydro- 10.0 kJ mol−1, using Arrhenius equation. As leaching of lanthanum in-
metallurgical process, for the recovery of precious metals unlike rare creased, the reaction rate was controlled by diffusion through an ash
earths. However there is complexity in extraction of lanthanum and layer. The apparent activation energy of the second stage was deter-
other rare earths from the slag obtained after pyro-treatment for the re- mined to be 24.8 kJ mol−1. The leaching rate and extent of leaching of
covery of other precious metals except rare earths (Acharya et al., 1999; lanthanum from the slag increased with an increase in leaching temper-
Das et al., 1986; Han and Fuerstenau, 1975; Koschinsky et al., 2011; ature (Kim et al., 2014).
Jung, 1993; Lokshin et al., 2002a, 2002b; Monhemius, 1986;
Senanayake, 2011; Zhang et al., 2001). Extraction of lanthanum and 2.9. Alternate methods of separating lanthanum
other rare earths from the sea nodules derived from Clarion–Clipperton
fracture zone (Korea mining site) of the North East Pacific Ocean was in- The conventional methodologies like solvent extraction and ion-ex-
vestigated with different reagents and the chemical composition were change has disadvantages such as high requirement of reagents, sec-
shown in Table 3. It has been found that the lanthanum extraction effi- ondary metabolites, and low selectivity in addition to more time
ciency with respect to each of the reagents can be ordered as consumption (Chunhua, 2007; Gupta and Krishnamurthy, 2004;
H2SO4 N H2SO3 + H2SO4 N NaOH NH2SO3. However, lanthanum leaching Kratochvil and Volesky, 1998; Takahashi et al., 2012; Tewari et al.,
efficiency increased with the H2SO4 concentration and maximum 2005; Xiong et al., 2012a, 2012b, 2013). Now-a-days adsorption catch-
recovery ~55.4% was attained at 3 M concentration, 10% pulp density, ing an eye with an emerging technique of bio-sorption, with an advan-
2 h, 30 °C (Parhi et al., 2013). tages over traditional way like cost efficient, high efficacy or selectivity
for metal extraction, regeneration with no chemical sludge and other
2.8. REE slag metabolite generation with an exclusive characteristics of faster kinetics
of adsorption and desorption, and its major applicability in situ process
Generally, REE slag was obtained from reduction smelting of magne- technologies (Akkaya, 2012; Kanazawa and Kamitani, 2006; Kratochvil
tite ore containing monazite. REE slag (derived from Hongcheongun in and Volesky, 1998; Palmieri et al., 2000; Takahashi et al., 2012; Tewari
Korea), was obtained by using silica (silica/ore: 1/50) as flux and coke et al., 2005; Das, 2012).
(coke/ore: 1/7.14) as a reducing agent for smelting in arc furnace for Adsorption of lanthanum have been attempted using different bio-
2 h at 1500 °C for iron extraction. However rare earth content in ores adsorbents like bacteria, activated carbon from rice husk, bamboo char-
originally as ~3% was concentrated to 9% REEs in the slag after iron re- coal and algae, among which algae was proven to be efficient one for
covery, where lanthanum content in REE slag makes up to 2.76 wt.% lanthanum uptake (Diniz and Volesky, 2005; Kratochvil and Volesky,
and the overall elemental composition were shown in Table 4 (Kim 1998; Palmieri et al., 2002; Qing, 2010). In this context, algae like Sar-
et al., 2014). Extraction of lanthanum via hydrometallurgical route gassum polysystum, Sargassum fluitans showed a potential for lantha-
was studied from REE slag under the conditions of 1.5 g slag per L in num uptake. However higher ability was observed using Pseudomonas
0.3 M H2SO4, 750 rpm, for 5 h at 30–80 °C. Leaching kinetics was species, and with ~ 98% lanthanum efficiently desorbed out from the
found to be described in two stages. The initial leaching rate was con- biomass using CaCO3 (Diniz and Volesky, 2005). Powdered tree leaves
trolled by chemical reaction, while the apparent activation energy of of Platanus orientalis or activated carbon from rice husk/agro-waste
S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59 55

Fig. 6. Process flow sheet for the recovery of (A, B) lanthanum chloride (Pietrelli et al., 2005; Li et al., 2009); (C) lanthanum oxalate (Fernandes et al., 2013) from spent NiMH batteries.

Table 3 materials are viable and inexpensive in use (Aoyama et al., 2000;
Chemical composition of deep sea nodules (Parhi et al., 2013). Awwad et al., 2010; Banat et al., 2003; Kazy et al., 2006; Nevskaia
Name of elements Concentration (mg/kg) et al., 1999; Xu and Xing, 2001). Different parameters influencing the
Y 94.03
adsorption process such as pH, temperature, biosorbent dosage, initial
La 100 metal concentration, contact period and agitation rate have also been
Ce 298 evaluated in these scanty studies. The pH dependence of lanthanum
Pr 37.7 bio sorption was observed efficiently in the range pH ~ 4–7, exceeding
Nd 148
which resulted in hydrolysis of the metal ions which leads to co-
Sm 37.9
Eu 10.3 precipitation of gelationous hydroxides (Esposito et al., 2001; Fiol
Gd 37.5 et al., 2006; Kazy et al., 2006; Palmieri et al., 2000; Qing, 2010; Sert
Tb 6.63 et al., 2008; Shibi and Anirudhan, 2005). However, the temperature of
Dy 32.6 ~25–35 °C have meagre effect but with the increase around 45 °C affect-
Ho 6.71
Er 16.7
ed the performance as reported using Agrobacterium sp. HN1, Calluna
Tm 2.68 vulgaris and Zoogloea ramigera (Aksu et al., 1992; Bhainsa and
Yb 1.61 D'Souza, 1999; Panda et al., 2006). Biosorbent dosage (~15–200 ppm)
Lu 2.7 in general is agreement with metal concentration range of 15–
Th 27.6
300 ppm in case of Agrobacterium sp. HN1, where lanthanum uptake in-
U 4.91
Mn 2,392,000 creases with cell concentration at 150 rpm and 30 °C (Shuxia et al.,
Fe 373,000 2011). Although, an increase in biomass concentration caused interfer-
Cu 8800 ence between the binding sites thus retaining the contact time to 5–8 h
Co 1530 (Esposito et al., 2001; Gadd et al., 1998; Pagnanelli et al., 2000). This tool
Ni 10,200
can be very specifically targeted to separate a relatively pure solution of
56 S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59

Table 4
Chemical composition of REE slag (Kim et al., 2014).

La Ce Pr Nd Sm Eu Gd Tb Dy Ho Er Tm Yb Lu U Fe Ca Mg Ba Sr Y

Element 2.76% 4.60% 0.41% 1.14% 830.7 158.5 278.1 23.5 53.6 5.4 16.8 0.8 9.0 1.6 1.8 0.7% 13.9% 7.1% 2.16% 9.84% 122
concentration ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm

lanthanum and other rare earth elements too, which can be a topic of solvent extraction. However, the co-extraction of metal impurities like
wide interest. iron, silica, titanium, rare earths and other trace impurities could inter-
fere in lanthanum extraction. Although the leaching is performed with
3. Future directions of research different mineral acids ranges from lower to higher concentration,
which inherently led to co-extraction of impurities in larger amount,
Lanthanum as an element commonly occurs in other metals ores and that actually interfere in purification/separation process like solvent ex-
different metallurgical waste residues. This review has put in place ef- traction and precipitation, inhibiting lanthanum purity. In respect of
forts to pile up the information about the different resources that these commonly used techniques, bio-sorption proves more influential
show some potential for the recovery of lanthanum namely monazite, with low cost and high selectivity. The main lessons learnt from this re-
bastnäsite, phosphate rock, bauxite, sea nodules, some industrial by- view address to the lack of selectivity by addressing a selective organic
products like phosphoric acid, phosphogypsum, red mud (Bauxite resi- extractant (acidic or neutral) in solvent extraction process, whilst frac-
due), REE slag and industrial products like optical spent glasses, Ni-MH tional precipitation and biosorption led to increase the overall efficiency
spent batteries. The overall summary is tabulated in Table 5. Bases on of lanthanum extraction. Therefore, it is necessary to develop new ex-
availability, content and recyclability, optical spent glasses, NiMH traction systems with high lanthanum selectivity or modify the existing
spent batteries are the most promising resources including the primary one in the areas of leaching and solvent extraction which overall im-
sources of monazite and bastnäsite. Considering lanthanum extraction proves the efficiency of lanthanum extraction. Since lanthanum is pro-
from aforementioned resources, hydrometallurgical processes is proven duced from various aforementioned resources, although there is need
to be most eminent process with an advantage of meagre energy con- to relocate more lanthanum containing resources like traces are
sumption and high efficiency compared to pyro-metallurgical process- ascertained in fly ash, blast furnace slag and flue dust, which actually
es, although the process consisting of ore pre-treatment, leaching, needed to explore so that it contributes as a useful part in the overall

Table 5
Leachability of lanthanum from various different resources and respective conditions.

Source Resource Pre-treatment Leaching Extraction Pulp Temperature References


description reagent (%) (g/L)

Monazite Primary, phosphate Dephosphorised with 50% NaOH HCl ~95 60 79–90 °C Kumari et al. (2013); Panda et al. (2014);
mineral (w/v) at 170 °C, 10% mixture of Shuchen et al. (2007); Shin et al. (2012);
NaCl–CaCl2, CaO–CaCl–CaCl2 Wenyuan et al. (2006)
Bastnäsite Primary, Sulfuric acid roasting H2SO4 ~90 30 60 °C Chi et al. (2004); Kanazawa and Kamitani
fluorocarbonate HCl ~98 30 90 °C (2006); Kul et al. (2000); Kul et al. (2008);
mineral Using MgO/ore: 0.15/1–3/1 H2O ~95 125 75 °C Wen-zhong et al. (2002a, 2002b); Xu (1995);
transformation of rare earth fluoride Zhang and Huang (1997), Zhu and Chi (1999);
to oxide followed direct ammonium Zhu et al. (2000a, 2000b); Zhu et al. (2003)
chloride roasting at 325 °C, 1 h
Bauxite Primary, aluminium Direct leaching HCl ~11 20 25 °C Ochsenkühn-Petropulu et al. (1996)
hydroxide mineral
Red mud Secondary, bauxite Direct leaching H2SO4 ~21–99.9 10–20 25–35 °C Abhilash et al. (2014); Ochsenkühn-Petropulu
residue HCl 33 20 et al. (1996); Ochsenkühn-Petropulu et al.
HNO3 35 20 (1995, 2002)
Phosphate rock Primary, phosphate Direct leaching H2SO4 45 20 25–45 °C Habashi (1985); Lokshin and Tareeva (2010),
rich sedimentary HCl 40 20 Lokshin et al. (2011)
rock HNO3 35 20
Phosphoric acid Secondary, Heating the acid in autoclave for 1 h HNO3 35 20 55 °C Bunuş and Dumitrescu (1992); Bunuş et al.
by-product of at 200 °C (crystals formed with 98% (1994); Habashi, 1985; Koopman et al. (1999a,
phosphate rock lanthanides) 1999b); Wang et al. (2010)
Phosphogypsum Secondary, Mechanical activation using ball H2SO4 ~78.5 100 Ambient Jarosiński et al. (1993);Habashi (1985); Lokshin
by-product of mill temperature and Tareeva (2010), Lokshin et al. (2011);
phosphate rock Todorovsky et al. (1997)
Spent nickel Secondary, spent Direct leaching H2SO4 ~92.5 100 20 °C Bertuol et al. (2009); Gasser and Aly (2013);
metal hydride mobile, laptop HCl ~97.8 40 25–35 °C Larsson et al. (2012); Li et al. (2009); Pietrelli
batteries batteries et al. (2002, 2005); Provazi et al. (2011);
Ruetschi et al. (1995); Zhang et al. (1998)
Optical spent Secondary, Conversion to hydroxide using hot HCl ~99.4 8 90 °C Jiang et al. (2004, 2005)
glasses microscope, conc NaOH (55 wt %) at 140 °C
binoculars, cameras
etc.
Ocean nodules Primary, Pacific Direct leaching H2SO4 ~55.4 10 35 °C Acharya et al. (1999); Anand et al. (1988);
Ocean nodules Fuerstuenau and Han (1977); Han and
Fuerstenau (1975); Jung (1993);Parhi et al.
(2013)
REE slag Secondary, Reduction smelting in arc furnace H2SO4 60–99.9 15 30–80 °C Kim et al. (2014)
reduction smelting for 2 h at 1500 °C for iron extraction
slag of magnetite
ore containing
monazite
S. Sinha et al. / Hydrometallurgy 160 (2016) 47–59 57

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