Selective recovery of rare earth elements by smelting of magnets

Rare earth elements (REEs) play a crucial role in many technologies from daily appliances in cell phones to more advanced wind turbines and electric cars. Permanent magnets account for a quarter of total global REEs production and have high recycling value. In this study, smelting process was used to selectively oxidize REEs in the permanent magnets by adding FeO. This separates REEs into a slag phase from an iron-rich metallic phase. BO was also added to the system as a flux to lower the slag melting temperature. This minimizes REEs loss to the metallic phase and allows a more efficient phase separation. The effect of flux and oxidizing agent addition was investigated on both regular and cerium-rich NdFeB (NdCeFeB) magnets. At 1350 °C and for 1 h, the slag phase was successfully separated from the metallic phase with the addition of 0.8 stoichiometric amount of FeO and 40 wt% of BO. Scanning electron microscopy–energy dispersive X-ray spectroscopy (SEM-EDX) analysis reveals that REEs in the magnet do not migrate to the metal phase while the REE-rich slag phase contains almost no iron. After the selective removal of iron into the metallic phase, REEs are recovered from the slag phase through an acid leaching process allowing >99% of REEs recovery. Boron in the magnet can also be recovered as useful boric acid by evaporation and crystallisation technique. The proposed process in this study is reagent and energy-efficient with almost complete valorisation of both NdCeFeB and NdFeB magnets.