Application of the Alternative Traditional and Selective Precipitation Routes for Recovery of High Grade Thorium Concentrates from Egyptian Crude Monazite Sand

Process flow sheet selection for thorium separation in relatively high grade concentrate from Egyptian crude monazite sand was carried out. Traditional selective leaching and precipitation routes were applied after sulfuric acid digestion upon Egyptian crude monazite for this purpose. The resultant hot grey sulfate paste from monazite digestion was firstly cooled to ambient temperature then leached by normal water into two successive stages. The first leach solution contained most of the thorium which represents about 88% of the present thorium and its concentration in the liquor reached 4.5 g Th/l. This liquor also contains most of the free acids and major of impurities especially iron (more than 6.3 g Fe/l). Different routes were tested to evaluate the suitable conditions that verify maximum recovery of thorium from such monazite sulfate solution and producing relatively high grade concentrate. Two different possible traditional and selective methods were involved, namely; thorium initial precipitation with rare earth elements as double sulfate or its precipitation as phosphate through acidity control at ph 1.1 which seems to be the simple, brief and convenient route to accomplish this purpose. Further separation and/or upgrading of thorium from these precipitates (after conversion to hydroxides or without) were conducted through re-dissolution in hydrochloric acid and re-precipitation with different selective reagents in the form of hydroxide, oxalate or fluoride was also included. The target was accomplished through thorium co-precipitation with light rare earth elements as double sulfate, followed by its recovery from this fraction, where a concentrate of grade 68.3% was produced