SAMPLE SOPs - RARE EARTH - BY NIK ZAFRI (QHSEL)

ALSO READ " RARE EARTH, THE MALAYSIAN EXPERIENCE " 

There should be a clear regulations of rare earth. The Mineral Development Act 1994 amendment should be a great start. I am aware that there are SOPs for sustainable mining for rare earth.

There are many types of rare earth and they are important to the development of modern day technology to name a few - aerospace components, metal halide/mercury vapor lamps, YAG laser, YVO, YS Zirconia, coatings of engines/turbines, electroceramic, solid oxile fuel cell, jewelry, Y Iron Garnet, even smart phones and so many more.

The regulations should take into account : 

a) separation and smelting, 

b) reserves should be determined and any unauthorized use should be fall under iilegal gain (to include procurement and export activities as well)

c) setting a quota and the penalty of anything exceeding the target 

d) when the law is in place, it should be unlawful to stop any inspection activities by the relevant authorities. 

Serious attention should also be given to the transparency in the Supply Chain involving rare earth alongside with a study of impact on the global market as well

The provided samples are for reference only and contains redacted information. It is not related to Malaysia's SOP on Rare Earth and requires further customization to ensure relevance and effectiveness.

1. Purpose

To establish standard practices for processing and extracting rare earth elements (REEs) from various ore sources using hydrometallurgical and pyrometallurgical methods, while ensuring safety, environmental compliance, and radiation protection.

2. Scope

Applicable to all personnel involved in beneficiation, leaching, roasting, solvent extraction, precipitation, and waste management at rare earth processing facilities in China.

3. Ore Types Handled

• Monazite (contains thorium, uranium – high radiation risk)
• Bastnäsite (low radioactivity)
• Xenotime (contains uranium, thorium)
• Ion-adsorption clay (common in southern China)
• Lateritic rare earth ore

4. Processing Methods Covered

• Crushing and Grinding
• Physical Beneficiation (magnetic, flotation, gravity)
• Acid/alkaline leaching
• Roasting (calcination, sulfation, chlorination)
• Solvent Extraction (SX), Ion Exchange
• Precipitation (oxalate, carbonate, hydroxide)
• Final product drying and calcining

5. Safety and PPE Requirements

• Full-body chemical protective suit
• Acid/alkali-resistant gloves and boots
• Face shield or goggles
• Respiratory protection (cartridge respirator or SCBA in roasting areas)
• Radiation dosimeter (for monazite, xenotime zones)
• Continuous ambient radiation monitoring system

6. Operational Procedure

6.1 Ore Preparation and Beneficiation

• Crushing and grinding to below 75–100 µm
• Apply physical separation (gravity, magnetic, flotation) based on ore characteristics.
• Collect tailings for NORM evaluation and containment.

 6.2 Hydrometallurgical Leaching

• Monazite/Xenotime: Alkaline (NaOH) or acid (H₂SO₄, HCl) leaching.
• Clay Ores: Leached with NH₄SO₄ or MgSO₄ at pH 4–6.
• Bastnäsite: Pre-roasting followed by acid leaching (HCl or H₂SO₄).

 Maintain:

• pH control (±0.1)
• Temperature: 50–90°C
• Residence time: 2–8 hours depending on ore

6.3 Pyrometallurgical Treatment (if required)

• Roasting with NaOH - Enhances REE liberation in monazite.
• Sulfation roasting - With H₂SO₄ for bastnäsite or mixed ores.
• Chlorination roasting - Optional for selective REE volatilization.
• Conduct in rotary kiln or fluidized bed under strict emission control.

6.4 Solid-Liquid Separation

• Use filter press or thickener to remove gangue solids.
• Test for radionuclide leach-out before tailings disposal.

6.5 Separation and Purification

Use Solvent Extraction (SX) with D2EHPA, PC88A, Cyanex 272, etc.

Multi-stage SX process for group separation:

• Light REEs (La–Nd)
• Middle REEs (Sm–Gd)
• Heavy REEs (Tb–Lu, Y)

Optimize:

• pH gradients (controlled by NH₄OH or NaOH)
• Aqueous-to-organic ratio
• Number of extraction and stripping stages

6.6 Precipitation and Final Product Recovery

• Use oxalic acid, ammonium carbonate, or NaOH.
• Filtration, washing, drying at 100–200°C.
• Calcination at 800–1000°C for oxide production.

7. Radiation Safety (NORM Management)

• Identify radionuclide content via gamma spectroscopy.
• Store radioactive residues in lined, shielded tailings ponds.
• Quarterly radiation survey of plant and personnel.

Follow China’s 《放射性矿产资源开发利用与环境保护规定》 (Regulations on Radioactive Mineral Development & Environmental Protection).

8. Environmental Management

• Acid/alkali neutralization before discharge.
• Zero Liquid Discharge (ZLD) where mandated.
• Emission scrubbers for SOx, NOx, HCl, HF.
• Solid waste monitored under GB standards.

9. Documentation & Records

• Batch processing logs
• Radiation exposure records
• Effluent and emissions monitoring logs
• Maintenance and incident reports

 10. References

• 《稀土工业污染物排放标准》(HJ 3075-2020)
• 《稀土工业清洁生产标准》(HJ/T 408-2007)
• IAEA NORM Safety Guide SSG-60
• GB Standards and local EPB (Environmental Protection Bureau) guidelines

1. Purpose

To establish comprehensive procedures for the processing, storage, quality control, delivery, sales, and customer follow-up of rare earth elements (REEs), ensuring product quality, safety, regulatory compliance, and customer satisfaction.

2. Scope

Covers the full value chain of REE operations in China: from ore reception to finished product delivery, including storage, logistics, sales, and post-sale support.

3. Key Sections Overview

• Ore Handling and Processing
• Product Storage and Inventory
• Delivery and Logistics
• Sales and Export Documentation
• Customer Follow-Up and After-Sales Service
• Radiation and Environmental Compliance
• Records and Documentation

4. Ore Handling and Processing

(Refer to previous SOP sections covering Crushing, Leaching, Roasting, SX, and Product Recovery.)

5. Product Storage and Inventory

5.1 Storage of Intermediate and Final Products

Use dedicated silos, bins, or sealed containers for:

• REE hydroxide, oxalate, carbonate, or oxide
• Grouped REEs (e.g., light, heavy REE mix)
• Individual oxides (e.g., Nd₂O₃, Dy₂O₃, La₂O₃)
• Maintain separate radiation-designated areas for monazite-derived products.
• Use humidity control and inert gas purging (N₂) where applicable.

5.2 Labelling and Segregation

 Clear product labels with:

• Batch number
• Product grade
• Radiation status (if applicable)
• Packing date and expiry (for specific applications)

5.3 Inventory Management

• Use ERP or digital inventory system.
• FIFO (First-In-First-Out) principle.
• Real-time stock balance monitoring.
• Daily reconciliation with dispatch records.

6. Delivery and Logistics

6.1 Packaging

• Use sealed, labeled, and moisture-resistant packaging.
• For export-grade REOs: follow customer packaging specifications.
• UN-approved containers for radioactive or hazardous materials.

6.2 Logistics Coordination

• Appoint a logistics coordinator (Screening/Vetting Required)
• Secure trucking with GPS tracking.

Verify documentation before dispatch:

• Bill of Lading
• Material Safety Data Sheet (MSDS)
• Radiation declaration (for monazite-derived products)
• Customs papers (if applicable)

6.3 Export Compliance

Register with China’s Ministry of Commerce for REE export quotas.

Prepare:

• Export license
• Environmental compliance certificate
• Customer’s End-User Declaration

7. Sales and Customer Follow-Up

7.1 Sales Documentation

• Quotation → Purchase Order → Proforma Invoice → Commercial Invoice
• Maintain customer-specific specs, lead times, and delivery conditions.

7.2 Sales Channels

• Direct to OEMs (e.g., magnets, catalysts, batteries)
• Traders with valid permits
• Export agents for international buyers

7.3 Customer Support and Follow-Up

Assign Key Account Managers (KAMs) for large buyers.

Post-delivery:

• Confirm receipt and satisfaction within 7 days.
• Provide technical documentation and usage guides.
• Collect customer feedback and register in CRM system.
• Offer assistance in application issues (e.g., solubility, particle size)

8. Radiation and Environmental Compliance (NORM)

• Clearly segregate NORM-related products and waste storage.
• Quarterly third-party audit of storage and transport practices.
• Adhere to Chinese and IAEA standards for all radioactive shipments.

9. Records and Documentation

10. Review and Update

This SOP shall be reviewed every 12 months or when:

• There are process changes
• Regulatory updates
• New export controls or NORM classifications