Neodymium-Praseodymium Separation Tank Selection
Neodymium-Praseodymium Separation Process Solution (NdCl3 + PrCl3 Mixed Nd-Pr Chloride or NdCl3-PrCl3 Solvent-Extraction Feed at 0.5-2.0 M Mixed Nd-Pr in 0.5-2 N Hydrochloric Acid HCl Plus PC-88A or P507 (2-Ethylhexyl 2-Ethylhexylphosphonate) Organic Extractant at 0.5-1.0 M PC-88A in Kerosene Plus Aliphatic-Diluent Multi-Stage Mixer-Settler Train at MP Materials Stage-2-NdPr-Restart, Lynas LAMP, Solvay La Rochelle, Iridium Bayan Obo, Hastings Yangibana, Pensana Saltend, and Shenghe Resources Refinery Operations) — Process-Water and Adjacency Tank Selection at NdPr Solvent-Extraction
Neodymium-praseodymium separation process solution (NdCl3 + PrCl3 mixed-Nd-Pr chloride solution at 0.5-2.0 M mixed Nd-Pr concentration + 0.5-2 N hydrochloric acid HCl + 60-70 C operating temperature; multi-stage countercurrent SX with PC-88A (2-ethylhexyl 2-ethylhexylphosphonate) or P507 organic extractant at 0.5-1.0 M PC-88A in kerosene + aliphatic-diluent at 30-100+ extraction-scrub-strip stage train; Pr preferentially loads PC-88A organic phase + scrubbed back into aqueous + Nd routes to raffinate at greater-than-99.99% Nd-and-Pr individual purity; downstream precipitation as Nd-oxalate + Pr-oxalate or Nd-carbonate + Pr-carbonate + calcination at 800-1100 C produces final Nd2O3 + Pr6O11 or NdPr-mixed-oxide for permanent-magnet feedstock at greater-than-99.5 wt% NdPr-oxide purity for downstream metal-reduction-and-magnet-alloy production at NdFeB sintered + bonded magnet manufacturing) is the dominant separation step for permanent-magnet applications at U.S. + Australian + European + Indian + Chinese REE-refinery operations including MP Materials Mountain Pass California Stage-2-NdPr-restart at 1,000-tpa-NdPr-oxide initial-target capacity + Lynas Rare Earths LAMP Kuantan Malaysia separation + Solvay La Rochelle France integrated separation + Iridium Bayan Obo Inner Mongolia integrated cracking-and-separation + Hastings Technology Metals Yangibana Project WA NdPr-FID + Pensana Saltend UK NdPr-from-Longonjo-Angola + Shenghe Resources Jiangxi China + Vital Metals Saskatoon Canada + Ucore Rare Metals Louisiana RapidSX-NdPr.
U.S. + Australian + European + Indian + Chinese rare-earth-element NdPr-separation supply is concentrated at major operators (MP Materials Mountain Pass California Stage-2-NdPr-restart targeting 1,000-tpa-NdPr-oxide initial output + Lynas Rare Earths LAMP Kuantan Malaysia + Solvay La Rochelle France integrated separation + Iridium Bayan Obo Inner Mongolia + Hastings Technology Metals Yangibana WA + Pensana Saltend UK + Shenghe Resources Jiangxi China + Vital Metals Saskatoon Canada + Ucore Rare Metals Louisiana RapidSX-NdPr + IREL Manavalakurichi India). Bulk hydrochloric-acid + caustic-soda + sodium-hydroxide + sodium-carbonate + ammonium-bicarbonate + oxalic-acid + PC-88A + P507 + kerosene-aliphatic-diluent adjacency reagent supply at the NdPr-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 + PC-88A 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 NdPr-separation operations.
1. Material Compatibility Matrix
NdPr-separation process solution at typical 0.5-2.0 M Nd + Pr + 0.5-2 N HCl + 60-70 C operating temperature + multi-stage SX with PC-88A organic phase is a moderately corrosive acidic-chloride solution with manageable corrosion envelope against polymeric construction at the working-strength specification, but with combined acid + organic-solvent + flammable-aliphatic-diluent fire-and-explosion 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), PC-88A + aliphatic-diluent fire envelope discipline (PC-88A 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 crud + interface-stability discipline (crud accumulation + organic-aqueous interface-stability + flooding + foaming + organic-loss is routine SX operating challenge; mixer-settler design + crud-management at every-shift inspection).
| Material | NdPr Chloride at 25C | NdPr Chloride at 70C | Notes |
|---|---|---|---|
| HDPE rotomolded | A | B | Standard at process-water + dilute-acid + reagent + adjacency 1500-10000-gal service; not at primary 70C 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 NdPr SX feed + raffinate + scrub + strip + product tank at 0.5-2.0 M Nd-Pr + 0.5-2 N HCl + 60-70 C across 5,000-200,000-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 NdPr-aqueous-phase storage at 50,000-500,000-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 NdPr precipitation reactor service |
| EPDM | A | A | Standard gasket at chloride service |
| Viton (FKM) | A | A | Standard at PC-88A 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 NdPr-separation operations is FRP vinyl-ester resin construction at 5,000-200,000-gallon scale for primary NdPr SX feed + raffinate + scrub + strip + product tank, HDPE-lined carbon-steel + PVDF-lined-steel at 50,000-500,000-gallon scale for primary NdPr-aqueous-phase containment, glass-lined-steel at premium-purity NdPr precipitation reactor service, Hastelloy C-276 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 NdPr-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 NdPr-separation operations; primary NdPr SX + storage at 5,000-500,000-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
Pr/Nd Solvent-Extraction Separation Train (Dominant Use). Mixed Pr-Nd chloride feed solution at 0.5-2.0 M total Pr-Nd + 0.5-2 N HCl + 60-70 C is processed through 30-100+ stage countercurrent mixer-settler SX train with PC-88A or P507 organic extractant at 0.5-1.0 M in kerosene + aliphatic-diluent. Pr preferentially loads PC-88A organic phase due to slightly higher pK + extraction-coefficient versus Nd; raffinate carries Nd at greater-than-99.99% Nd purity; loaded organic is scrubbed with dilute-HCl + Pr stripped with concentrated-HCl back into aqueous as Pr chloride at greater-than-99.99% Pr purity. Storage envelope: 5,000-200,000-gallon FRP vinyl-ester or HDPE-lined-steel SX feed + raffinate + scrub + strip tank.
NdPr-Mixed-Oxide Final-Product (Permanent Magnet Feedstock). Some operators produce NdPr-mixed-oxide at greater-than-99.5 wt% NdPr-oxide purity at LREE-cracking + light-SX without full Nd-Pr separation; downstream precipitation as NdPr-mixed-oxalate or NdPr-mixed-carbonate + calcination at 800-1100 C produces NdPr-mixed-oxide for permanent-magnet feedstock at NdFeB sintered + bonded magnet manufacturing (Hitachi Metals + Shin-Etsu Chemical + TDK + Daido Steel + Ningbo-Yunsheng + Magnequench). Storage envelope: 5,000-100,000-gallon FRP vinyl-ester or HDPE-lined-steel NdPr-mixed precipitation reactor.
Individual Nd-Oxide and Pr-Oxide Final-Product. Individual high-purity Nd2O3 + Pr6O11 oxide at greater-than-99.99% individual-REE-oxide purity is produced for specialty-magnet + ceramic + glass + catalyst markets at downstream precipitation-and-calcination step. Storage envelope: 5,000-50,000-gallon glass-lined-steel + 316L-stainless + FRP vinyl-ester precipitation reactor.
Sm-Eu-Gd Light-Group SX Train. Continuing LREE separation downstream of NdPr-separation: Sm + Eu + Gd are separated at PC-88A + Cyanex 272 + EHEHPA SX train with EuCl3 + EuCl2 reduction-extraction-via-amalgam or zinc-reduction at downstream specialty-Eu-recovery step. Storage envelope: 5,000-50,000-gallon FRP vinyl-ester or HDPE-lined-steel SX tank.
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 NdPr-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 + PC-88A + P507 + kerosene-aliphatic-diluent handling at NdPr-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. PC-88A + P507 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. NdPr 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. Nd-Pr-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 PC-88A + 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.
EPA NPDES + State Refinery-Discharge Permit. NdPr-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 NdPr chloride + PC-88A 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 PC-88A + 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. Neodymium and praseodymium 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 MP Materials Mountain Pass + Lynas Texas separation provides domestic-NdPr support framework.
4. Storage System Specification
Primary NdPr SX Tank (OUTSIDE OneSource HDPE Scope). Primary NdPr SX feed + raffinate + scrub + strip + product tank at 5,000-500,000-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 NdPr-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.
PC-88A-Aliphatic-Diluent Organic-Phase Tank (Outside HDPE Scope). PC-88A or P507 in kerosene-aliphatic-diluent organic-phase storage at 5,000-100,000-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 NdPr 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 NdPr 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. NdPr-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. PC-88A + P507 + 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.
Crud Management Discipline. Crud accumulation + organic-aqueous interface-stability + flooding + foaming + organic-loss is routine SX operating challenge; mixer-settler design with proper mixer + settler residence + stage-loading + crud-removal at every-shift inspection is critical; routine 30-day crud-skimmer + interface-cleaner + hot-water-flush procedure.
Acid + Organic Spill Response. Acidic NdPr 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 + PC-88A + P507 + 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. PC-88A + kerosene-aliphatic-diluent require NFPA 30 + IFC Chapter 57 grounding-bonding + Hot Work Permit at off-loading.
QC Sampling and Verification. Each NdPr-SX-feed + Nd-raffinate + Pr-strip + Nd-product + Pr-product sample collection: total-REE per ICP-MS + ICP-AES + individual Nd + Pr 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.
Spent-Organic-Phase Management. Spent PC-88A + 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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