Leaching the Unleachable Mineral: Rare Earth Dissolution from Monazite Ore in Condensed Phosphoric Acid

Monazite is a poorly soluble mineral of rare earth phosphate. It is an ore of the rare earths which is difficult to break down; in industry either concentrated sulphuric acid or caustic soda is used to attack finely ground monazite at between 140 °C and 400 °C. In these processes, the rare earths are converted into different solid compounds, undergoing an incomplete conversion. Here we show a new process for a direct and much faster breakdown of monazite by simple dissolution under milder conditions. Condensed phosphoric acid was used to dissolve rare earths (up to 96 g/L) from unground monazite sand from four sources. Greater than 99% of light rare earths dissolved within 30 min at 260 °C. The cooled solution can be diluted to an extent with water to reduce viscosity for analysis or further processing. This method of dissolution avoids the use of strong acids/bases and reduces the risk of dusk exposure from fine grinding of particles.