Liquid is a crucial medium to contain soluble oxygen, valuable metal ions, and bacteria in unsaturated heap leaching. Liquid retention behavior is the first critical issue to be considered to efficiently extract low-grade minerals or wastes. In this study, the residual liquid holdup of an unsaturated packed bed was quantitatively discussed by liquid holdup (θ), residual liquid holdup (θ_residual), relative liquid holdup (θ′), and relative porosity (n*) using the designed measuring device. The detailed liquid holdup and the hysteresis behavior under stepwise irrigation are indicated and discussed herein. The results show that relative porosity of the packed bed was negatively related to particle size, and intra-particle porosity was more developed in the −4.0 + 2.0 mm packed bed. The higher liquid retention of the unsaturated packed bed could be obtained by using stepwise irrigation (incrementally improved from 0.001 to 0.1 mm/s) instead of uniform irrigation (0.1 mm/s). It could be explained in that some of the immobile liquid could not flow out of the unsaturated packed bed, and this historical irrigation could have accelerated formation of flow paths. The θ was sensitive to superficial flow rate (or irrigation rate) in that it obviously increased if a higher superficial flow rate (u) was introduced, however, the θ_residual was commonly affected by n* and θ′. Moreover, the liquid hysteresis easily performed under stepwise irrigation condition, where θ and θ_residual were larger at u of the decreasing flow rate stage (DFRS) instead of u of the increasing flow rate stage (IFRS). These findings effectively quantify the liquid retention and the hysteresis behavior of ore heap, and the stepwise irrigation provides potential possibility to adjust liquid retention conditions.

Oolitic hematite ore represents a significant iron resource, but its utilization is challenging due to the complex multi-layered circular structure of hematite ore, which makes it difficult to be reduced. This study systematically investigated the phase transformation principle and magnetite grain growth law during the magnetization sintering of oolitic hematite ore, aiming to establish optimal conditions for efficient hematite ore to magnetite conversion. The results demonstrated that both elevated temperature and prolonged reduction duration significantly enhanced the reduction efficiency of hematite (Fe₂O₃) to magnetite. The optimal sintering conditions were determined to be 700 °C for 45 min, under which the magnetite content and Fe/O atomic ratio in the roasted products peaked at approximately 68% and 0.8%, respectively. However, temperatures exceeding 800 °C proved detrimental to magnetite formation, as further reduction to Fe_XO phases occurred. Notably, appropriate temperature elevation promoted substantial magnetite grain growth. When the sintering temperature increased from 600 °C to 700 °C, both the absolute and relative thickness of the magnetite layer exhibited remarkable enhancement, expanding from 9.52 μm to 76.76 μm and from 5.99% to 50.33%, respectively. Furthermore, comparative analysis revealed that a high sintering temperature for a short time was more effective for magnetite particle growth than a low temperature for a long time in the magnetization process of oolitic hematite ore.

Medium and heavy rare earths (REEs) are mainly from weathered crust elution-deposited rare earth ores (WREOs), where REEs are adsorbed in ionic form on the surface of clay minerals such as kaolinite, illite, halloysite, etc. REEs in WREOs are extracted through the in situ leaching process with (NH₄)₂SO₄ solution via ion exchange. However, this process often results in the swelling of clay minerals, subsequently destroying the ore body structure and causing landslides. This study investigated the inhibitory effects of humic acid (HA) on the swelling of primary clay minerals. An optimal inhibition on the swelling of clay minerals was demonstrated at 0.2 g/L. HA was mixed with 0.1 mol/L (NH₄)₂SO₄ solution at the solution pH of 6.8 and temperature of 25 °C. The swelling efficiency of kaolinite, illite, and halloysite in presence of HA decreased by 0.29%, 1.19%, and 0.19%, respectively, compared to using (NH₄)₂SO₄ alone. The surface hydration parameter of clay minerals was further calculated through viscosity theory. It was demonstrated that the surface hydration parameter of kaolinite and halloysite decreased nearly threefold, while that of illite decreased fivefold, demonstrating a desirable inhibition on clay swelling with HA. Viscosity theory offers valuable theoretical support for the development of anti-swelling agents.

Bauxite residue is a hazardous solid waste produced in the alumina production process and has also become a significant rare earth resource. The extraction behaviors of La, Ce, Sc and Y solubilized in the phosphoric acidic leachate of bauxite residue were investigated in this study with di-(2-ethylhexyl) phosphoric acid as the extractant. With a relatively low concentration of 2% at an aqueous solution pH of 1.5, 90% Sc and 98% Y were extracted by di-(2-ethylhexyl) phosphoric acid. Less than 5% La and Ce and impurities of Fe, Al, Ti and Ca were extracted in this situation. As the concentration of di-(2-ethylhexyl) phosphoric acid increased to 20%, almost all the Sc and Y were extracted and the extraction ratios of La and Ce were 87% and 95%, respectively. A good separation of REEs against impurities was simultaneously obtained in the solvent extraction process and their separation coefficients were much higher than 1. A stepwise extraction process was proposed and established to extract Sc/Y and La/Ce sequentially from the phosphoric acidic leachate. It was further revealed that the Sc and Y in the acidic leachate were extracted by di-(2-ethylhexyl) phosphoric acid through an ion exchange process, and that the extraction of La and Ce was due to an antagonistic process where both an ion exchange reaction and a solvation reaction occurred.