Dysprosium-Terbium Separation Tank Selection
Dysprosium-Terbium Separation Process Solution (DyCl3 + TbCl3 Mixed Heavy-REE Chloride Solvent-Extraction Feed at 0.05-0.5 M Mixed Dy-Tb in 0.5-2 N Hydrochloric Acid HCl Plus Cyanex 272 (Di-2,4,4-Trimethylpentyl-Phosphinic-Acid) Organic Extractant at 0.5-1.0 M Cyanex 272 in Kerosene Plus Aliphatic-Diluent Multi-Stage Mixer-Settler Train at Lynas LAMP, Solvay La Rochelle, Iridium Bayan Obo, Northern Minerals Browns Range, Hastings Yangibana, Ucore Rare Metals RapidSX, Vital Metals Saskatoon, and Shenghe Resources HREE Refinery Operations) — Process-Water and Adjacency Tank Selection at HREE Solvent-Extraction
Dysprosium-terbium separation process solution (DyCl3 + TbCl3 mixed-Dy-Tb chloride solution + adjacent Ho-Er-Tm-Yb-Lu heavy-rare-earth chloride feed at 0.05-0.5 M mixed Dy-Tb concentration + 0.5-2 N hydrochloric acid HCl + 60-70 C operating temperature; multi-stage countercurrent SX with Cyanex 272 (di-2,4,4-trimethylpentyl-phosphinic-acid) or Cyanex 923 (trialkyl-phosphine-oxide) organic extractant at 0.5-1.0 M in kerosene + aliphatic-diluent at 60-150+ extraction-scrub-strip stage train; Tb preferentially loads Cyanex 272 organic phase + Dy routes to raffinate at greater-than-99.99% Dy-and-Tb individual purity; downstream precipitation as Dy-oxalate + Tb-oxalate + calcination at 800-1100 C produces final Dy2O3 + Tb4O7 oxide for permanent-magnet additive + phosphor + nuclear-control-rod feedstock at greater-than-99.95 wt% individual-HREE-oxide purity for downstream metal-reduction-and-magnet-alloy production at NdFeB sintered + bonded magnet manufacturing) is the dominant heavy-rare-earth separation step at U.S. + Australian + European + Indian + Chinese REE-refinery operations including Lynas Rare Earths LAMP Kuantan Malaysia separation + Solvay La Rochelle France integrated separation + Iridium Bayan Obo Inner Mongolia integrated cracking-and-separation + Northern Minerals Browns Range WA HREE-FID + Hastings Technology Metals Yangibana WA + Ucore Rare Metals Louisiana RapidSX-HREE + Vital Metals Saskatoon Canada HREE-feed + Shenghe Resources Jiangxi China + IREL Manavalakurichi India HREE.
U.S. + Australian + European + Indian + Chinese rare-earth-element HREE-separation supply is concentrated at major operators (Lynas Rare Earths LAMP Kuantan Malaysia separation + Solvay La Rochelle France integrated separation + Iridium Bayan Obo Inner Mongolia + Northern Minerals Browns Range WA HREE + Hastings Technology Metals Yangibana WA + Ucore Rare Metals Louisiana RapidSX-HREE + Vital Metals Saskatoon Canada + Shenghe Resources Jiangxi China + IREL Manavalakurichi India). Bulk hydrochloric-acid + caustic-soda + sodium-hydroxide + sodium-carbonate + ammonium-bicarbonate + oxalic-acid + Cyanex 272 + Cyanex 923 + kerosene-aliphatic-diluent adjacency reagent supply at the HREE-separation facility is conventional industrial-chemical procurement.
The eight sections below cite OSHA Hazard Communication 29 CFR 1910.1200 + 1910.1000 hydrochloric-acid + flammable-aliphatic-diluent + Cyanex 272 organic-vapor air-contaminant ceiling + IAEA NORM-TENORM + 10 CFR 20 NRC source-material license + 40 CFR 192 EPA UMTRCA + ASTM D511 Cl + ASTM D1971 metals + EPA Method 6010 + 6020 ICP-AES + ICP-MS REE analytical + EPA NPDES + state-specific refinery-discharge permit + EPA SPCC + state-specific NORM-TENORM tailings code + EPA RCRA Subtitle C + Bevill exemption + DOT 49 CFR 173 + NFPA 30 Class IIIA + IIIB combustible-liquid + IFC Chapter 57 + 40 CFR 63 NESHAP organic-vapor + DOE NDAA Sec 154 critical-mineral source + Defense Production Act Title III rare-earth + Defense Logistics Agency Strategic and Critical Stockpile + EXIM Bank financing framework at routine operating practice at North American + Australian + European + Asian HREE-separation operations.
1. Material Compatibility Matrix
HREE-separation process solution at typical 0.05-0.5 M Dy + Tb + 0.5-2 N HCl + 60-70 C operating temperature + multi-stage SX with Cyanex 272 organic phase is a moderately corrosive acidic-chloride solution at lower-REE-concentration than LREE-circuit but with longer SX-train + higher-stage-count + smaller-volume + premium-purity envelope. Operating-discipline controls: temperature discipline (60-70 C operating range at SX train accelerates chloride attack on 304 + 316L stainless above 60 C; FRP vinyl-ester + PVDF preferred at heated chloride service), free-acid-strength discipline (0.5-2 N HCl free acid is moderate; HDPE acceptable at less-than-2 N at ambient; FRP vinyl-ester acceptable at higher concentration + temperature), Cyanex 272 + aliphatic-diluent fire envelope discipline (Cyanex 272 at 0.5-1.0 M in kerosene-or-aliphatic-diluent flash point 50-70 C is NFPA 30 Class IIIA combustible liquid; explosion-proof electrical + grounding-bonding + fire-suppression + spill-containment), and HREE-cost discipline (HREE feed-and-reagent-cost is dramatically higher than LREE-circuit; tighter inventory control + smaller batch size + premium-purity + radiation-control + lower-loss tolerance).
| Material | HREE Chloride at 25C | HREE Chloride at 70C | Notes |
|---|---|---|---|
| HDPE rotomolded | A | B | Standard at process-water + dilute-acid + reagent + adjacency 1500-10000-gal service; not at primary 70C HREE-SX-train mixer-settler service |
| XLPE rotomolded | A | B | Standard at process-water + adjacency reagent service |
| FRP vinyl-ester resin | A | A | STANDARD at primary HREE SX feed + raffinate + scrub + strip + product tank at 0.05-0.5 M Dy-Tb + 0.5-2 N HCl + 60-70 C across 1,000-50,000-gallon scale |
| FRP isophthalic polyester | B | C | Acceptable at dilute service only; vinyl-ester preferred |
| PVDF (Kynar) lined steel | A | A | Premium at higher-temperature concentrated-chloride service |
| HDPE-lined carbon steel | A | A | Standard at primary HREE-aqueous-phase storage at 5,000-50,000-gallon scale |
| 304 stainless steel | C | NR | NOT recommended; chloride-induced pitting + crevice corrosion at any service |
| 316L stainless steel | B | C | Acceptable at very-dilute ambient service only |
| Hastelloy C-276 | A | A | Premium at higher-temperature concentrated-chloride + organic-phase service |
| Glass-lined steel | A | A | STANDARD at premium-purity HREE precipitation reactor service |
| EPDM | A | A | Standard gasket at chloride service |
| Viton (FKM) | A | A | Standard at Cyanex 272 organic-phase + chloride service |
| PTFE | A | A | Premium gasket + diaphragm + valve seat at concentrated-chloride + organic-phase service |
| PVC Sch 80 | A | B | Standard at ambient-temperature dilute-chloride piping; not above 60 C |
| CPVC Sch 80 | A | A | Preferred at 60-95 C reagent + transfer piping |
The dominant industrial pattern at U.S. + Australian + European + Asian HREE-separation operations is FRP vinyl-ester resin construction at 1,000-50,000-gallon scale for primary HREE SX feed + raffinate + scrub + strip + product tank, glass-lined-steel + Hastelloy C-276 at premium-purity individual-HREE-oxide precipitation reactor, HDPE-lined carbon-steel at 5,000-50,000-gallon scale for HREE-aqueous-phase containment, PVDF-lined-steel at concentrated-chloride + organic-phase pump + valve trim, and HDPE rotomolded tanks at the process-water + hydrochloric-acid-makedown + caustic-makedown + soda-ash + oxalic-acid + sodium-carbonate + ammonium-bicarbonate + flocculant + reagent + analytical-lab + adjacency 1,500-10,000-gallon scale outside the primary HREE-SX-train mixer-settler circuit. OneSource Plastics' 5-brand HDPE network (Norwesco, Snyder Industries, Chem-Tainer, Enduraplas, Bushman) covers the process-water + hydrochloric-acid-makedown + caustic-makedown + soda-ash + oxalic-acid + sodium-carbonate + ammonium-bicarbonate + flocculant + reagent adjacency envelope at HREE-separation operations; primary HREE SX + storage at 1,000-50,000-gallon scale requires FRP vinyl-ester + PVDF-lined-steel + HDPE-lined-steel + glass-lined-steel + Hastelloy + 316L-stainless construction OUTSIDE our HDPE 5-brand scope, and we refer those specifications to qualified specialty-alloy + glass-lined + FRP vinyl-ester + PVDF-lining tank fabricators.
2. Real-World Industrial Use Cases
HREE Solvent-Extraction Separation Train (Dominant Use). Mixed Sm-Eu-Gd + Tb-Dy-Ho-Er-Tm-Yb-Lu + Y heavy-rare-earth + middle-rare-earth chloride feed solution at 0.05-0.5 M total HREE + 0.5-2 N HCl + 60-70 C is processed through 60-150+ stage countercurrent mixer-settler SX train with Cyanex 272 or Cyanex 923 + PC-88A organic extractant at 0.5-1.0 M in kerosene + aliphatic-diluent. HREE separation order is Lu-Yb-Tm-Er-Ho-Y-Dy-Tb-Gd-Eu-Sm at Cyanex 272 + Cyanex 923 + PC-88A multi-train with HREE preferentially loading at higher distribution-coefficient versus LREE; Tb preferentially loads versus Dy at the Tb/Dy split-train; Y separates between Dy + Ho due to ionic-radius position. Storage envelope: 1,000-50,000-gallon FRP vinyl-ester or HDPE-lined-steel SX feed + raffinate + scrub + strip tank.
Individual Dy-Oxide and Tb-Oxide Final-Product (Permanent Magnet + Phosphor). Individual high-purity Dy2O3 + Tb4O7 oxide at greater-than-99.95% individual-REE-oxide purity is produced for permanent-magnet additive (Dy-Tb dopant in NdFeB sintered magnet for high-temperature performance) + phosphor + nuclear-control-rod + specialty-laser-host markets at downstream precipitation-and-calcination step. Storage envelope: 1,000-25,000-gallon glass-lined-steel + 316L-stainless + FRP vinyl-ester precipitation reactor.
Y-Eu-Tb Phosphor-Group Separation. Y + Eu + Tb separation at Cyanex 272 + PC-88A SX train produces Y2O3 + Eu2O3 + Tb4O7 phosphor-grade oxide at greater-than-99.999% purity for fluorescent + LED + cathode-ray-tube phosphor markets at downstream specialty-phosphor production. Storage envelope: 1,000-25,000-gallon glass-lined-steel + 316L-stainless + FRP vinyl-ester precipitation reactor.
Lu-Yb-Tm-Er-Ho Specialty-HREE Final-Product. Individual high-purity Lu2O3 + Yb2O3 + Tm2O3 + Er2O3 + Ho2O3 oxide at greater-than-99.95% individual-REE-oxide purity is produced for laser-host + medical-imaging-PET + dosimetry + fiber-optic-amplifier + nuclear-medicine markets at downstream specialty-HREE production. Storage envelope: 500-10,000-gallon glass-lined-steel + 316L-stainless precipitation reactor.
Process Water and Reagent Adjacency. Process water + hydrochloric-acid-makedown + caustic-makedown + soda-ash-makedown + oxalic-acid + sodium-carbonate + ammonium-bicarbonate + flocculant + reagent adjacency at the HREE-separation facility uses HDPE rotomolded 1,500-10,000-gallon storage in the standard chemical-process 5-brand network.
3. Regulatory Framework
OSHA 29 CFR 1910.1200 + 1910.1000 + 1910.1450 Hazard Communication. Hydrochloric-acid + caustic-soda + sodium-carbonate + oxalic-acid + ammonium-bicarbonate + Cyanex 272 + Cyanex 923 + kerosene-aliphatic-diluent handling at HREE-separation facility requires OSHA Hazard Communication SDS + container labeling + PPE specification (chemical splash goggles + face shield + chemical splash suit + chemical-resistant glove + steel-toe boots + supplied-air or air-purifying respirator with HCl + organic-vapor + NORM-aerosol cartridge + eye-wash + emergency shower per 1910.151 within 10 seconds of work area + designated trained operator + radiation-area-worker dosimetry framework at TENORM-impacted area).
NFPA 30 Class IIIA Combustible Liquid and IFC Chapter 57. Cyanex 272 + Cyanex 923 + PC-88A in kerosene-aliphatic-diluent flash point 50-70 C is NFPA 30 Class IIIA combustible liquid + IFC Chapter 57 flammable-and-combustible-liquid storage code; explosion-proof electrical Class I Division 1 or 2 + grounding-bonding + fire-suppression CO2 or AFFF foam + spill-containment + max storage 240 gallon indoor + 1320 gallon outdoor per state Fire Marshal + IFC Chapter 57 + NFPA 30 limits.
IAEA NORM-TENORM and 10 CFR 20 NRC Source Material License. HREE feed solution at less-than-0.1 ppm Th + less-than-0.05 ppm U post-cracking-and-separation is essentially radiation-clean; mother-liquor + recycle stream may carry trace activity under 10 CFR 20 NRC source-material license framework + 40 CFR 192 UMTRCA + state-specific radiation-control-program. Operator dose-rate survey + ALARA program + dosimetry at TENORM-impacted-area worker is mandatory.
EPA RCRA Subtitle C + Bevill Exemption. HREE-bearing residue + spent organic phase + mother-liquor classify based on residual REE + Cl + Th + U content; Bevill exemption applies to mining-extracted ore + tailings under 40 CFR 261.4(b)(7); but spent Cyanex + kerosene + aliphatic-diluent organic phase classifies as RCRA hazardous waste under D001 ignitable + D002 corrosive + F-list spent-solvent characteristic.
EPA Method 6010 + 6020 ICP-AES + ICP-MS REE Analytical. EPA SW-846 Method 6010C ICP-AES + 6020B ICP-MS at every NPDES + RCRA + state radiation-control compliance sample for total-REE quantification + Th + U + Ra-226 + Pb-210. ASTM D1971 metals analytical framework. Cl by IC + acid-base titration. HREE individual-REE separation analytical at 0.001 wt% individual-REE-impurity measurement.
EPA NPDES + State Refinery-Discharge Permit. HREE-separation discharge to surface water requires state-specific refinery-discharge permit + EPA NPDES outfall + radiation-monitoring + reclamation-bond framework at every operating refinery.
EPA SPCC + State NORM-TENORM Tailings Code. Acidic HREE chloride + Cyanex 272 organic-phase storage requires double-liner + leak-detection + secondary-containment + radiation-shielded-containment per state-specific NORM-TENORM tailings + radioactive-source-material code + Spill Prevention Control and Countermeasure Plan + flammable-and-combustible-liquid spill-containment.
40 CFR 63 NESHAP and DOT 49 CFR 173. 40 CFR 63 NESHAP at Cyanex + organic-vapor stack emission + DOT 49 CFR 173 hydrochloric-acid UN 1789 + oxalic-acid UN 1760 + caustic-soda UN 1824 transport classification.
DOE NDAA Sec 154 Critical-Mineral Source and Defense Production Act Title III. Dysprosium + terbium + holmium + erbium + thulium + ytterbium + lutetium are designated critical minerals; U.S. DOD Industrial Base + DLA Strategic and Critical Stockpile + EXIM Bank financing + DOE Rare Earth Demonstration Plant Wheat Ridge Colorado + DPA Title III investment in Northern Minerals Browns Range + Ucore Rare Metals RapidSX provides domestic-HREE support framework.
4. Storage System Specification
Primary HREE SX Tank (OUTSIDE OneSource HDPE Scope). Primary HREE SX feed + raffinate + scrub + strip + product tank at 1,000-50,000-gallon scale uses FRP vinyl-ester resin construction with C-veil chemical-resistant interior corrosion-barrier + structural-laminate + UV-resistant exterior gel-coat per ASTM D3299 + D4097 specification, or HDPE-lined carbon-steel construction with 250-mil rotational-molded HDPE liner + secondary-containment + leak-detection per state code, or PVDF-lined or glass-lined-steel + Hastelloy C-276 construction at higher-purity service. This specification is OUTSIDE OneSource Plastics' HDPE 5-brand scope; we refer those specifications to qualified specialty-alloy + glass-lined + FRP vinyl-ester + PVDF-lining tank fabricators.
Process Water and Reagent-Makedown Tank (HDPE Scope). Process-water + hydrochloric-acid-makedown + caustic-makedown + soda-ash-makedown + oxalic-acid-makedown + sodium-carbonate + ammonium-bicarbonate + flocculant-makedown + reagent makedown at the HREE-separation facility uses 1,500-10,000-gallon HDPE or XLPE rotomolded vertical flat-bottom or shallow-cone-bottom atmospheric tank, 1.85 specific-gravity rated, mounted on level reinforced-concrete pad with secondary containment via integral catch-basin or external concrete-bermed pad sized to 110% of largest-tank volume; 3-4 inch flanged top fill + atmospheric vent; 2-3 inch flanged bottom outlet with full-bore PVC ball valve; 18-24 inch top manway; ultrasonic level transmitter; sample valve; opaque-pigmented HDPE for UV protection at outdoor service; freeze-protection insulation + heat-trace at northern-state operation.
Cyanex-Aliphatic-Diluent Organic-Phase Tank (Outside HDPE Scope). Cyanex 272 + Cyanex 923 + PC-88A in kerosene-aliphatic-diluent organic-phase storage at 1,000-25,000-gallon scale uses 316L-stainless or FRP vinyl-ester construction with NFPA 30 Class IIIA + IFC Chapter 57 flammable-and-combustible-liquid containment, explosion-proof electrical + grounding-bonding + fire-suppression. Outside HDPE-rotomolded scope.
Radiation-Area Containment. All HREE SX + storage at TENORM-impacted area requires radiation-shielded secondary containment + leak-detection + double-liner + concrete-bermed-pad with epoxy or polyurea topcoat + dose-rate monitoring + final-status-survey at decommissioning per 10 CFR 20 + 40 CFR 192 + state-specific radiation-control-program.
Containment and Spill Pad. All HREE aqueous-phase + organic-phase storage requires secondary containment per EPA SPCC + state-specific NORM-TENORM tailings + flammable-and-combustible-liquid spill-containment code; concrete-bermed pad with HDPE primary + secondary liner + leak-detection sump + acid + organic-resistant epoxy or polyurea topcoat + radiation-survey at access.
5. Field Handling Reality
Handler PPE. HREE-separation-area entry: full-face supplied-air or air-purifying respirator with HCl + organic-vapor + NORM-aerosol cartridge for routine open-system handling, chemical splash suit + chemical-resistant apron at any open-system handling, double nitrile or neoprene chemical-resistant glove at any contact, chemical splash goggles + face shield, steel-toe boots with chemical-resistant overshoe, eye-wash + emergency shower per OSHA 29 CFR 1910.151 within 10 seconds of work area, dosimetry-badge framework at TENORM-impacted-area worker, designated trained-operator + ALARA-program + Hot Work Permit + flammable-and-combustible-liquid handling discipline at every TENORM-impacted task.
Fire and Explosion Discipline. Cyanex 272 + Cyanex 923 + PC-88A + kerosene-aliphatic-diluent organic-phase area requires NFPA 30 Class IIIA + IFC Chapter 57 flammable-and-combustible-liquid storage code; explosion-proof electrical Class I Division 1 or 2 + grounding-bonding + fire-suppression CO2 or AFFF foam + spill-containment + max storage 240 gallon indoor + 1320 gallon outdoor per state Fire Marshal + IFC Chapter 57 + NFPA 30 limits + Hot Work Permit + line-break-protocol + fire-watch + emergency-evacuation drill + annual fire-suppression-system inspection.
HREE Inventory Discipline. HREE feed-and-reagent-cost is dramatically higher than LREE-circuit (Tb at $1500-3000/kg + Dy at $300-500/kg + Lu at $700-1500/kg versus Nd-Pr at $50-100/kg); tighter inventory control + smaller batch size + premium-purity + radiation-control + lower-loss tolerance + tighter mass-balance + every-stage sample collection + organic-phase loss-tracking is critical for HREE economics.
Acid + Organic Spill Response. Acidic HREE aqueous-phase + organic-phase spill response: small-volume aqueous spill is contained at secondary-containment + neutralized in place with soda-ash or lime + sampled to less-than-0.5 N free acid + transferred via vacuum-truck to event-pond or process recycle. Organic-phase spill triggers fire-protection response + foam-suppression + spill-recovery to recycle. Large-volume spill triggers state-agency notification + radiation-survey + downstream water-quality + dose-rate sampling + fire-protection mobilization.
Cargo-Tank Receipt and Reagent Off-Loading. Hydrochloric-acid + caustic-soda + soda-ash + oxalic-acid + sodium-carbonate + Cyanex 272 + Cyanex 923 + kerosene-aliphatic-diluent bulk delivery: tanker pre-transfer site-survey + chemical-suit + supplied-air-respirator + Buddy-system + transfer-rate-monitoring + leak-detection + emergency-deluge per OSHA 1910.120 HAZWOPER. Rail-tank-car ISO-tank delivery is dominant format. Cyanex + kerosene-aliphatic-diluent require NFPA 30 + IFC Chapter 57 grounding-bonding + Hot Work Permit at off-loading.
QC Sampling and Verification. Each HREE-SX-feed + Dy-raffinate + Tb-strip + Dy-product + Tb-product sample collection: total-REE per ICP-MS + ICP-AES + individual Dy + Tb + Ho + Er + Tm + Yb + Lu + Y distribution per ICP-MS at every-stage + free-HCl per acid-base titration + Th + U + Ra-226 per gamma-spec at TENORM-impacted-stream + pH continuous + grab confirmation + specific-gravity + temperature continuous + organic-aqueous distribution-coefficient at routine-stage sampling + HREE individual-REE-impurity measurement at 0.001 wt% precision.
Spent-Organic-Phase Management. Spent Cyanex 272 + Cyanex 923 + kerosene-aliphatic-diluent organic phase at end-of-cycle classifies as RCRA hazardous waste D001 + D002 + F-list spent-solvent + requires DOT-permitted hazwaste-hauler removal to qualified TSDF for thermal-destruction or solvent-recovery.
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