Abstract: Acid digestion, extraction, sedimentation, burning etc. are included in the ion-type rare earth sepa - ration and production processes. Characteristics of the hazardous substances used in smelting and separation process and dangers that are poisoning, burning, mechanical injuries in the production process are analyzed. The fire resistance rating of extraction workshop is low and fire prevention zone does not meet the safety re - quirements. Analyzing the dangerous and harmful factors in production process and using butterfly catastrophe theory to establish the ion-type rare earth smelting separation enterprise safety production guarantee system and the degree of risk definition and classification model of mutation series is of great significance to the en - terprise management and production of rare earth smelting separation.