Samarium-Cobalt Feed Tank Selection

Samarium-Cobalt Feed Process Solution (SmCl3 + CoCl2 or SmSO4 + CoSO4 Mixed Sm-Co Chloride or Sulfate Solvent-Extraction Feed at 0.3-1.5 M Sm + 0.3-1.5 M Co in 0.5-2 N HCl or H2SO4 Plus PC-88A or Cyanex 272 Multi-Stage Mixer-Settler Train Producing Sm2O3 Samaria Final Oxide and Co3O4 Cobalt Oxide Precursor for SmCo5 and Sm2Co17 High-Temperature Permanent-Magnet Alloy Production at MP Materials, Lynas LAMP, Solvay La Rochelle, Iridium Bayan Obo, Treibacher Industrie, IREL Manavalakurichi, Vital Metals, and Shenghe Resources Refinery Operations) — Process-Water and Adjacency Tank Selection at SmCo Magnet Feed

Samarium-cobalt feed process solution (SmCl3 + CoCl2 or Sm2(SO4)3 + CoSO4 mixed-Sm-Co chloride or sulfate solution at 0.3-1.5 M Sm + 0.3-1.5 M Co concentration + 0.5-2 N HCl or H2SO4 + 60-70 C operating temperature; multi-stage countercurrent SX with PC-88A or Cyanex 272 organic extractant at 0.5-1.0 M in kerosene + aliphatic-diluent at 30-100+ extraction-scrub-strip stage train; Sm preferentially loads PC-88A organic phase versus adjacent LREE La-Ce-Pr-Nd; Sm-stripped product back into aqueous as purified Sm chloride or sulfate at greater-than-99.99% Sm purity; downstream precipitation as Sm-oxalate + calcination at 800-1100 C produces final Sm2O3 samaria oxide at greater-than-99.95 wt% Sm2O3 purity; co-process Co recovery from CoCl2 or CoSO4 solution via Cyanex 272 SX + Co-precipitation produces final CoO + Co3O4 + CoSO4 cobalt-precursor for SmCo5 + Sm2Co17 high-temperature permanent-magnet alloy production at downstream metal-reduction-and-magnet-alloy step at SmCo magnet manufacturing; SmCo magnets serve aerospace + military + medical-imaging-MRI + high-temperature-motor markets at NdFeB-displaced applications) is the dominant Sm-and-Co separation step at U.S. + Australian + European + Indian + Chinese REE-refinery operations including MP Materials Mountain Pass California Stage-2-NdPr-and-Sm-restart adjacency + Lynas Rare Earths LAMP Kuantan Malaysia separation + Solvay La Rochelle France integrated separation + Iridium Bayan Obo Inner Mongolia + Treibacher Industrie Althofen Austria specialty-Sm-and-Co + IREL Manavalakurichi India + Vital Metals Saskatoon Canada + Shenghe Resources Jiangxi China.

U.S. + Australian + European + Indian + Chinese SmCo-feed-and-precursor supply is concentrated at major operators (MP Materials Mountain Pass California Stage-2-NdPr-and-Sm + Lynas Rare Earths LAMP Kuantan Malaysia separation + Solvay La Rochelle France integrated separation + Iridium Bayan Obo Inner Mongolia + Treibacher Industrie Althofen Austria + IREL Manavalakurichi India + Vital Metals Saskatoon Canada + Shenghe Resources Jiangxi China; downstream SmCo-magnet manufacturing at Arnold Magnetic Technologies Lupfig Switzerland + EEC Magnetics + Electron Energy Corporation Landisville Pennsylvania + Hitachi Metals + TDK + Shin-Etsu Chemical + Daido Steel + Ningbo-Yunsheng + Chinese sintered-magnet manufacturers). Bulk hydrochloric-acid + sulfuric-acid + caustic-soda + sodium-carbonate + ammonium-bicarbonate + oxalic-acid + PC-88A + Cyanex 272 + kerosene-aliphatic-diluent adjacency reagent supply at the Sm-and-Co separation facility is conventional industrial-chemical procurement.

The eight sections below cite OSHA Hazard Communication 29 CFR 1910.1200 + 1910.1000 hydrochloric-acid + sulfuric-acid + cobalt-aerosol + 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 + Co 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 + Co-aerosol + IARC Group 2A carcinogen Co + soluble-Co + EU REACH SVHC cobalt-sulfate + cobalt-chloride + Authorisation List Annex XIV + DOE NDAA Sec 154 critical-mineral source + Defense Production Act Title III rare-earth + Co + Defense Logistics Agency Strategic and Critical Stockpile + EXIM Bank financing framework at routine operating practice at North American + Australian + European + Asian SmCo-feed operations.

1. Material Compatibility Matrix

SmCo SX process solution at typical 0.3-1.5 M Sm + 0.3-1.5 M Co + 0.5-2 N HCl or H2SO4 + 60-70 C operating temperature + multi-stage SX with PC-88A or Cyanex 272 organic phase is a moderately corrosive acidic-chloride or acidic-sulfate 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 plus Co-aerosol carcinogen-class envelope. Operating-discipline controls: temperature discipline (60-70 C operating range at SX train accelerates chloride or sulfate attack on 304 + 316L stainless above 60 C; FRP vinyl-ester + PVDF preferred at heated chloride or sulfate service), free-acid-strength discipline (0.5-2 N HCl or H2SO4 free acid is moderate; HDPE acceptable at less-than-2 N at ambient; FRP vinyl-ester acceptable at higher concentration + temperature), PC-88A + Cyanex + aliphatic-diluent fire envelope discipline (PC-88A + 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 Co-aerosol carcinogen discipline (cobalt + soluble-Co cation is IARC Group 2A carcinogen + EU REACH SVHC + Authorisation List Annex XIV; supplied-air respirator + chemical-suit + dedicated changeroom + medical-monitoring + bioassay framework at every Co-aerosol-impacted task).

The dominant industrial pattern at U.S. + Australian + European + Asian Sm + Co separation operations is FRP vinyl-ester resin construction at 5,000-200,000-gallon scale for primary SmCo SX feed + raffinate + scrub + strip + product tank, glass-lined-steel + Hastelloy C-276 at premium-purity Sm2O3 + CoO precipitation reactor at greater-than-99.95% purity, HDPE-lined carbon-steel + PVDF-lined-steel at 50,000-500,000-gallon scale for SmCo-aqueous-phase containment, and HDPE rotomolded tanks at the process-water + hydrochloric-acid-makedown + sulfuric-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 SmCo-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 + sulfuric-acid-makedown + caustic-makedown + soda-ash + oxalic-acid + sodium-carbonate + ammonium-bicarbonate + flocculant + reagent adjacency envelope at SmCo-feed operations; primary SmCo 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

Sm Solvent-Extraction Separation Train (Dominant Use). Mixed Sm-Eu-Gd middle-rare-earth chloride or sulfate feed solution at 0.3-1.5 M total Sm-Eu-Gd + 0.5-2 N HCl or H2SO4 + 60-70 C is processed through 30-100+ stage countercurrent mixer-settler SX train with PC-88A or Cyanex 272 organic extractant at 0.5-1.0 M in kerosene + aliphatic-diluent. Sm separates from Eu + Gd at the Sm/Eu split-train; Sm preferentially loads at PC-88A versus Eu + Gd; Sm-stripped product back into aqueous as purified Sm chloride or sulfate at greater-than-99.99% Sm purity. Storage envelope: 5,000-200,000-gallon FRP vinyl-ester or HDPE-lined-steel SX feed + raffinate + scrub + strip tank.

Sm2O3 Samaria Final-Product (SmCo Magnet Feedstock). Purified Sm chloride or sulfate at greater-than-99.99% Sm is precipitated as Sm-oxalate at pH 1-2 with oxalic-acid + 60-80 C aging + filtration + drying; cake calcined at 800-1100 C to Sm2O3 samaria final product at greater-than-99.95 wt% Sm2O3 purity for SmCo5 + Sm2Co17 high-temperature permanent-magnet alloy production at downstream metal-reduction-and-magnet-alloy step. Storage envelope: 5,000-50,000-gallon glass-lined-steel + 316L-stainless + FRP vinyl-ester precipitation reactor.

Co-Process Cobalt Recovery (Cyanex 272 SX + Co-Precipitation). Cobalt-bearing chloride or sulfate solution at 0.3-1.5 M Co + 0.5-2 N HCl or H2SO4 is processed through Cyanex 272 SX at pH 4.5-5.5 + Co-Ni separation + Co preferentially loads Cyanex 272 organic phase versus Ni; Co-stripped product back into aqueous as purified CoCl2 or CoSO4 at greater-than-99.95% Co purity; downstream precipitation as Co-oxalate or Co-carbonate or Co-hydroxide + calcination at 600-900 C produces final CoO + Co3O4 + CoSO4 cobalt-precursor at greater-than-99.95 wt% Co purity. Storage envelope: 5,000-200,000-gallon FRP vinyl-ester or HDPE-lined-steel Co-SX tank.

SmCo5 + Sm2Co17 Magnet Alloy Production. Sm2O3 + Co3O4 + reductant (Ca + Ba + La metal) is processed through metallothermic-reduction at 1000-1200 C in argon-or-vacuum environment producing SmCo5 + Sm2Co17 magnet alloy ingot; magnet alloy is jet-milled to powder + pressed-aligned in magnetic field + sintered at 1100-1200 C + heat-treated to optimum-coercivity for SmCo magnet downstream production. Storage envelope: 1,000-25,000-gallon glass-lined-steel + 316L-stainless + FRP vinyl-ester reagent + slurry tank.

Process Water and Reagent Adjacency. Process water + hydrochloric-acid-makedown + sulfuric-acid-makedown + caustic-makedown + soda-ash-makedown + oxalic-acid + sodium-carbonate + ammonium-bicarbonate + flocculant + reagent adjacency at the SmCo-feed 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 + sulfuric-acid + caustic-soda + sodium-carbonate + oxalic-acid + ammonium-bicarbonate + cobalt-soluble-aerosol + PC-88A + Cyanex 272 + kerosene-aliphatic-diluent handling at SmCo-feed 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 respirator with HCl + H2SO4 + Co-aerosol + organic-vapor + NORM-aerosol cartridge + eye-wash + emergency shower per 1910.151 within 10 seconds of work area + designated trained operator + Co-aerosol carcinogen-class medical-monitoring + bioassay framework at every Co-aerosol-impacted task).

NFPA 30 Class IIIA Combustible Liquid and IFC Chapter 57. PC-88A + Cyanex 272 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.

IARC Group 2A Carcinogen Co + EU REACH SVHC + Authorisation List Annex XIV. Cobalt + soluble-Co cation is IARC Group 2A carcinogen + EU REACH SVHC + Authorisation List Annex XIV at cobalt-sulfate + cobalt-chloride + cobalt-nitrate substance specification; supplied-air respirator + chemical-suit + dedicated changeroom + medical-monitoring + bioassay framework at every Co-aerosol-impacted task is mandatory.

IAEA NORM-TENORM and 10 CFR 20 NRC Source Material License. Sm + Co 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. Sm + Co bearing residue + spent organic phase + mother-liquor classify based on residual Sm + Co + Cl + SO4 + Th + U content; Bevill exemption applies to mining-extracted ore + tailings under 40 CFR 261.4(b)(7); but Co-bearing waste may classify as RCRA hazardous waste under D006 cadmium + D008 lead trace + Co-specific characteristic; spent PC-88A + Cyanex 272 + 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 + Co Analytical. EPA SW-846 Method 6010C ICP-AES + 6020B ICP-MS at every NPDES + RCRA + state radiation-control compliance sample for total-REE + Co quantification + Th + U + Ra-226 + Pb-210 activity-concentration. ASTM D1971 metals analytical framework. Cl by IC + acid-base titration. SO4 by IC.

EPA NPDES + State Refinery-Discharge Permit. SmCo-separation discharge to surface water requires state-specific refinery-discharge permit + EPA NPDES outfall + Co + radiation-monitoring + reclamation-bond framework at every operating refinery.

EPA SPCC + State NORM-TENORM Tailings Code. Acidic SmCo chloride or sulfate + PC-88A + 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.

DOE NDAA Sec 154 Critical-Mineral Source and Defense Production Act Title III. Samarium + cobalt 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-Sm-and-Co support framework.

4. Storage System Specification

Primary SmCo SX Tank (OUTSIDE OneSource HDPE Scope). Primary SmCo 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 + sulfuric-acid-makedown + caustic-makedown + soda-ash-makedown + oxalic-acid-makedown + sodium-carbonate + ammonium-bicarbonate + flocculant-makedown + reagent makedown at the SmCo-feed 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 or Cyanex 272 Organic-Phase Tank (Outside HDPE Scope). PC-88A or Cyanex 272 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.

Co-Aerosol Carcinogen Containment. All Co-bearing aerosol-generating area (calcination off-gas + dust collection + filter cake handling + drying-oven exhaust) requires HEPA filtration + dedicated changeroom + supplied-air respirator + chemical-suit + medical-monitoring + bioassay framework + IARC Group 2A carcinogen-management + EU REACH SVHC compliance.

Containment and Spill Pad. All SmCo 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. SmCo-separation-area entry: full-face supplied-air respirator with HCl + H2SO4 + Co-aerosol + 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 + medical-monitoring + bioassay framework at every Co-aerosol-impacted task.

Fire and Explosion Discipline. PC-88A + Cyanex 272 + 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.

Co-Aerosol Carcinogen Discipline. Co-aerosol carcinogen-class IARC Group 2A + EU REACH SVHC + Authorisation List Annex XIV requires supplied-air respirator + chemical-suit + dedicated changeroom + medical-monitoring + bioassay framework at every Co-aerosol-impacted task + dedicated tooling + dust-collection HEPA + drying-oven exhaust capture + filter-cake handling enclosure.

Acid + Organic + Co-Aerosol Spill Response. Acidic SmCo 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. Co-aerosol release triggers HEPA-respirator + dedicated-changeroom-decontamination + medical-monitoring follow-up. 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 + sulfuric-acid + caustic-soda + soda-ash + oxalic-acid + sodium-carbonate + PC-88A + Cyanex 272 + 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.

QC Sampling and Verification. Each SmCo-SX-feed + Sm-raffinate + Co-raffinate + Sm-strip + Co-strip + Sm-product + Co-product sample collection: total-REE + Co per ICP-MS + ICP-AES + individual Sm + Eu + Gd + Co + Ni distribution per ICP-MS at every-stage + free-HCl or H2SO4 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 + Cyanex 272 + 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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