Search Results (4)

To address the critical challenges in pyrometallurgical recycling processes—such as poor feedstock adaptability, high energy consumption during roasting conversion, and the low added value of rare earth products—this study systematically investigated the mechanism and process optimization of ammonium bifluoride (NH₄HF₂) roasting for the recovery of neodymium–iron–boron (NdFeB) waste. Thermodynamic analysis confirmed the feasibility of the conversion reaction between NH₄HF₂ and the rare earth components in NdFeB waste. Single-factor experiments were conducted to examine the effects of roasting temperature, reaction time, and NH₄HF₂ dosage on rare earth recovery. The optimal conditions were a roasting temperature of 600 °C, a reaction time of 120 min, and a NH₄HF₂ dosage of 75 wt%, achieving a rare earth recovery rate of 98.81%. Furthermore, the response surface methodology (RSM) was employed to establish a quantitative model correlating process parameters with recovery efficiency. Variance analysis demonstrated that the model was highly significant (F = 136.94, p < 0.0001), with excellent agreement between actual and predicted values (R² = 0.9944). Factor contribution analysis revealed that NH₄HF₂ dosage had the most pronounced impact on rare earth fluorination, followed by roasting temperature and reaction time. Under optimized conditions, the purified rare earth fluoride obtained after acid leaching reached a purity of 99.43%, providing high-quality raw material for producing high-value-added rare earth products. Full article

Neodymium-Iron-Boron (NdFeB) based permanent magnets are indispensable in today’s technology-driven society. Moreover, their use is likely to increase since they are key in clean energy applications such as wind turbines, hybrid/electric vehicles, and electric bikes. They contain critical raw materials as rare earth elements are used. Indeed, permanent magnets are considered strategic materials by the EU, and their recycling represents a potential secondary supply to decrease the import dependence. The VALOMAG project is developing a technical solution to recover rare earth (RE) based permanent magnets by dismantling end-of-life (EoL) products such as computer hard disc drives, electric motors, and generators from electric vehicles and wind turbines. It also assesses two short loop recycling technologies: Hydrogen Decrepitation (HD) or Hydrogenation–Disproportionation–Desorption–Recombination (HDDR) and strip-casting for high and medium quality magnet wastes; and hydrometallurgical processes for EoL low-quality magnets. Moreover, Life Cycle Assessment (LCA) and Process Integration with a Flowsheet simulation tool will integrate the whole recycling value chain (collection, dismantling, physical and chemical treatment options, and re-manufacturing) and assess the environmental impact and processes efficiency. A market study on the types and expected future quantities for the scrap magnets and the characterisation of the EoL magnets from hard disc drives (HDD) will be presented as preliminary results. Pre-treatment and sorting of 2.5 tons of NdFeB magnets scraps were carried out, and the two short loop recycling routes and the hydrometallurgical route are under investigation at the lab and pilot scale. The results will be used to develop a process integration and to assess the three routes through LCA. Full article

Hydrogen decrepitation (HD) is an effective and environmentally friendly technique for recycling of neodymium-iron-boron (NdFeB) magnets. During the HD process, the NdFeB breaks down into a matrix phase (Nd₂Fe₁₄BH_x) and RE-rich grain boundary phase. The grain boundary phase in the HD powder is <2 μm in size. Recycled NdFeB material has a higher oxygen content compared to the primary source material. This additional oxygen mainly occurs at the Rare Earth (RE) rich grain boundary phase (GBP), because rare earth elements oxidise rapidly when exposed to air. This higher oxygen level in the material results in a drop in density, coercivity, and remanence of sintered NdFeB magnets. The particle size of the GBP is too small to separate by sieving or conventional screening technology. In this work, an attempt has been made to separate the GBP from the matrix phase using a hydrocyclone, and to optimise the separation process. HD powder, obtained from hard disk drive (HDD) scrap NdFeB sintered magnets, was used as a starting material and passed through a hydrocyclone a total number of six times. The X-ray fluorescence (XRF) analysis and sieve analysis of overflows showed the matrix phase had been directed to the underflow while the GBP was directed to the overflow. The optimum separation was achieved with three passes. Underflow and overflow samples were further analysed using an optical microscope and MagScan and matrix phase particles were found to be magnetic. Full article

The pretreatment processes consisting of grinding followed by roasting were investigated to improve the selective leaching of Nd and Dy from neodymium-iron-boron (NdFeB) magnet scraps. The peaks of Nd(OH)₃ and Fe were observed in XRD results after grinding with NaOH as the amount of water addition increased to 5 cm³. These results indicate that the components of Nd and Fe in NdFeB magnet could be changed successfully into Nd(OH)₃ and Fe, respectively. In the roasting tests using the ground product, with increasing roasting temperature to 500 °C, the peaks of Nd(OH)₃ and Fe disappeared while those of Nd₂O₃ and Fe₂O₃ were shown. The peaks of NdFeO₃ in the sample roasted at 600 °C were observed in the XRD pattern. Consequently, 94.2%, 93.1%, 1.0% of Nd, Dy, Fe were leached at 400 rpm and 90 °C in 1 kmol·m⁻³ acetic acid solution with 1% pulp density using a sample prepared under the following conditions: 15 in stoichiometric molar ratio of NaOH:Nd, 550 rpm in rotational grinding speed, 5 cm³ in water addition, 30 min in grinding time, 400 °C and 2 h in roasting temperature and time. The results indicate that the selective leaching of Nd and Dy from NdFeB magnet could be achieved successfully by grinding and then roasting treatments. Full article