Rare earth elements (REEs) recovery and porous silica preparation from kaolinite

A kaolinite containing 245 ppm of REEs was used as a feedstock for REE recovery. Acid leaching test results showed that less than 20% of the REEs were leached using 1.2 mol/L HCl. However, after thermal treatment at 600 °C, a recovery of over 80% was obtained with a much lower acid concentration (0.01 mol/L). Meanwhile, only 3.91% Al, 2.34% Fe, 8.63% K, 9.32% Mg, 0.08% Ti, and 5.34% Ca were simultaneously extracted. Therefore, high-purity rare earth products are likely produced from the kaolinite. To achieve a more comprehensive utilization of the kaolinite, the residual solid after REE recovery was subjected to a selective leaching process to prepare porous silica. Comparisons among three different types of mineral acids showed that H₂SO₄ provided the best performance. The effects of different factors were investigated using the response surface methodology. A porous silica with as high as 336.95 m²/g specific surface area was ultimately produced.