Integrated acid leaching and biological sulfate reduction of phosphogypsum for REE recovery

•REE dissolution from PG was increased from < 1% to up to 62% with 0.05 M H2SO4.•Sulfate-reducing bioreactor was successfully operated with acidic PG leachate.•REE concentrated phases in the final precipitate reached 2.54% of the total sample. Sulfuric acid leaching of phosphogypsum (PG) waste and leachate treatment in sulfate-reducing bioreactor was studied, in order to recover rare earth elements (REE) and remove sulfate from the residual solution. The challenge was to balance efficient REE extraction from PG while maintaining suitable leach solution acidity and sulfate concentration for the microorganisms in the bioreactor. Stirred tank reactor experiments were conducted for PG leaching to form the scope for suitable sulfuric acid concentration and REE leaching efficiency. According to these experiments, moderate REE leaching started already at 0.01 M H2SO4 concentration (yield 6–15%), and increased steadily when increasing H2SO4 concentration to 0.05 M (yield 34–62%). Different leachates were treated in sulfate-reducing bioreactor to understand the limits of acidity and sulfate concentration for the biological system. It was shown that bioreactor requires rather a mild leachate (