To reveal the ion-exchange mechanism in the leaching process of weathered crust elution-deposited rare earth ores with different leaching agents, the effects of a variety of cations and anions at different concentrations on the leaching process were investigated, including Al³⁺, Fe³⁺, Ca²⁺, Mg²⁺, Na⁺, K⁺, NH4+ and Cl⁻, NO3-, and SO42-. Meanwhile, the relationships between different concentrations of cations and anions and leaching efficiency were investigated, as was the relationship between different concentrations of cations and anions and zeta potential. The effect of different ions on the swelling of clay minerals during leaching process was also investigated. The results shown that NH4+ was the most affected electrolyte cation in terms of rare earth leaching efficiency during the leaching process of weathered crust elution-deposited rare earth ore among three different cationic valence states, and the leaching efficiency was 86.93% at the optimal leaching concentration. The influence of the three anions on the leaching efficiency of rare earth was NO3->Cl->SO42-, and the leaching efficiency of rare earth were 83.21, 81.52, and 80.12% at the optimal leaching concentration, respectively. The NH4+ had the greatest effect on the zeta potential of weathered crust elution-deposited rare earth ore, and the zeta potential was −18.1 mV at the optimal leaching concentration. Additionally, the order of the effect of three anions on zeta potential was SO42->NO3->Cl-. Combined with the effect on the rare earth leaching process, anions and cations were considered separately, and NH4+ and Cl⁻ were selected; the relationship between the rare earth leaching efficiency and zeta potential conforms to the follow equations: NH4+:Y = −0.48X² – 13.51X – 1.58, R² = 0.98133 and Cl⁻:Y= −1.22X² – 17.64X + 23.29, R² = 0.99010. It was also found in the swelling experiment of the weathered crust elution-deposited rare earth ore that the swelling ratio of clay minerals was the lowest when the cation and anion were NH4+ and Cl⁻ and the swelling ratios were 1.874 and 2.015%, respectively.

To reveal the regularity of variation in the rare earth occurrence states of weathered crust elution-deposited rare earth ores, ore samples from different weathering crust layers were obtained by performing the sequential extraction procedure. The order of rare earth contents firmly obeyed the following sequence: the weathered layer > humic layer > partly weathered layer. The occurrence states of rare earth elements were mainly the ion exchange state, carbonate bound state, iron–manganese oxide state, organic binding state and residual state. The proportions of rare earth elements found in the rare earth ion exchange state of the weathered layer, humic layer and partly weathered layer were 78.55%, 73.53% and 53.88%, respectively. The light rare earth elements (LREEs) found in the rare earth ion exchange state were enriched in the upper part of the weathering crust, while the heavy rare earth elements (HREEs) were enriched in the lower part. There were also obvious negative anomalies in the content of cerium in the ion exchange state. The content of rare earth elements found in the carbonate bound state was small, and the rare earth partition pattern was basically consistent with that of the ion exchange state, which had little effect on the differentiation of the rare earth elements. The iron–manganese oxide state was mainly enriched with cerium, and the content of cerium increased with the depth of the weathering crust. The iron–manganese oxide state was the main factor causing the phenomenon of the anomaly in the cerium content. Meanwhile, the iron oxides in the iron–manganese oxide state were mainly hematite and goethite. The organic binding state mainly beneficiated yttrium and cerium by complexation and certain adsorption. The content of elements found in the rare earth residual state was related to the degree of weathering and reflected the release sequence of rare earth elements in the mineralization process. Clarifying the rare earth occurrence states is conducive to better revealing the metallogenic regularity of weathered crust elution-deposited rare earth ores. In addition, the results can provide a valuable reference for expanding the available rare earth resources and the efficient comprehensive utilization of rare earth ore.

To unveil the impact of each condition variable on the leaching efficiency index during the heap leaching process of rare earth ore and establish a prediction model for leaching conditions and efficiency, common parameters in the heap leaching process of rare earth ore were selected. In addition, the pilot-scale test data were collected over 50 days. Based on the collected data, the Ordinary Least Squares (OLS) linear regression method was used for fitting analysis to determine each variable’s influence on the change in leaching efficiency. The results indicated a linear relationship between the flow rate of the leaching solution and leaching efficiency. In contrast, no obvious linear relationship was observed between other condition variables and leaching efficiency. Spearman’s rank correlation coefficient was calculated to analyze the nonlinear correlation between the abovementioned variables and the leaching efficiency index. The correlation coefficients were found to be −0.78, 0.88, −0.93, −0.53, 0.71, and −0.93 for ammonium content in the leaching agent, pH of the leaching agent, rare earth content, ammonium content in the leaching solution, pH of the leaching solution, and the flow rate of the leaching solution, respectively. This suggests that the flow rate of the leaching solution, rare earth content, and pH of the leaching agent significantly influence leaching efficiency, thus affecting the rare earth leaching efficiency index. Based on the correlation analysis results of leaching conditions and efficiency, a dataset with limited data trained by the common Ordinary Least Squares model, linear regression model, random forest model, and support vector machine regression model was selected to develop a prediction model for the leaching process data. The results indicated that the random forest model had the lowest mean square error of 7.47 among the four models and the coefficient of determination closest to 1 (0.99). This model can effectively analyze and predict condition variables’ data and leaching efficiency index in the heap leaching process of rare earth ore, with a prediction accuracy exceeding 90%, thus providing intelligent guidance for the heap leaching process of rare earth ores.

This paper investigates the rare earth (RE) leaching process of weathered crust leached rare earth ores (WCE-DREOs) with different ore particle sizes. Ore particles were categorized into seven distinct size ranges: −0.106 mm, +0.106 mm to −0.15 mm, +0.15 mm to −0.25 mm, +0.25 mm to −0.85 mm and +0.85 mm. The study examined the correlation between the thickness of the electrical double layer (EDL) and the RE content, as well as the swelling ratio of clay minerals. The findings demonstrated that the order of RE content with respect to varying particle sizes was as follows: ${\mathrm{C}}_{-0.106}>{\mathrm{C}}_{+0.106~-0.15}>{\mathrm{C}}_{+0.15~-0.25}>{\mathrm{C}}_{+0.25~-0.85}>{\mathrm{C}}_{+0.85}$ (C represents RE content). The RE content of full particle size was found to be 7.93 mg/g, with the particle size −0.106 mm exhibiting the highest RE content of 2.02 mg/g. In the fitting of the relationship between the RE content and the thickness of the EDL, it was observed that the particle size −0.106 mm exhibited a consistent correlation with the Logistic function $\mathrm{y}=2.03-0.43/(1+{\left(1.49\mathrm{x}\right)}^{172.39})$. In the study of the swelling performance of the WCE-DREOs, the order of the swelling ratio of ore samples in different particle sizes was ${\delta }_{-0.106}>{\delta }_{+0.106~-0.15}>{\delta }_{+0.15~-0.25}>{\delta }_{+0.25~-0.85}>{\delta }_{+0.85}$($\mathsf{\delta }$ represents the swelling ratio), and the swelling ratio was 3.34%, 2.92%, 2.33%, 1.55% and 0.01%, respectively. In the fitting of the relationship between the swelling ratio of clay minerals and the thickness of the EDL, it was observed that a particle size of −0.106 mm corresponded to the exponential function $\mathrm{y}=3.65-99.89·\exp \left(-\mathrm{x}/0.12\right)$. The results of the study provide useful assistance in the mining of the WCE-DREOs.