• Suspension roasting achieves rapid bastnaesite decomposition with simultaneous cerium oxidation, yielding CO2, Ce7O12, La2O3, CeF3, and LaF3 as products.
• Prolonged roasting initially increases surface cracks, porosity, and BET specific surface area, but later particle fusion and pore consolidation reduce specific surface area.
• Both bastnaesite pyrolysis and cerium oxidation follow Avrami–Erofeev kinetic models; reaction order decreases with temperature, and activation energy is higher at lower temperatures.
• The study provides mechanistic insights and kinetic parameters essential for optimizing suspension roasting technology in bastnaesite smelting and rare earth extraction.
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