Recovery of Fine Rare Earth Minerals from Simulated Tin Tailings by Carrier Magnetic Separation: Selective Heterogeneous Agglomeration with Coarse Magnetite Particles

The demand for rare earth elements (REEs) is continuously increasing due to the important roles they play in low-carbon and green energy technologies. Unfortunately, the global REE reserves are limited and concentrated in only a few countries, so the reprocessing of alternative resources like tailings is of critical importance. This study investigated carrier magnetic separation using coarse magnetite particles as a carrier to recover finely ground monazite from tailings. The monazite and carrier surfaces were modified by sodium oleate (NaOL) to improve the hydrophobic interactions between them. The results of zeta potential and contact angle measurements implied the selective adsorption of NaOL onto the surfaces of the monazite and magnetite particles. Although their hydrophobicity increased, heterogenous agglomeration between them was not substantial. To improve heterogenous agglomeration, emulsified kerosene was utilized as a bridging liquid, resulting in more extensive attachment of fine monazite particles onto the surfaces of carrier particles and a dramatic improvement in monazite recovery by magnetic separation—from 0% (without carrier) to 70% (with carrier). A rougher–scavenger–cleaner carrier magnetic separation can produce REE concentrates with a total rare earth oxide (TREO) recovery of 80% and a grade of 9%, increased from 3.4%, which can be further increased to 23.2% after separating REEs and the carrier.