NdFeB Magnets Recycling via High‑Pressure Selective Leaching and the Impurities Behaviors

Global concerns about climate change are driving increased demand of electric vehicles for sustainable transportation and turbines in emerging energy solutions, where permanent magnets (PMs) and rare earth elements (REEs) play a critical role. However, global REEs recycling rates are only 3% and 8% for light and heavy REEs, respectively. This work proposes an effective approach to separate the REEs and iron via high-pressure selective leaching by low-concentrated nitric acid from the end-of-life NdFeB magnet and investigates the impurities behavior during the leaching and precipitation steps. The results from the optimized leaching conditions demonstrated over 95% REEs leaching efficiency with less than 0.3% Fe dissolution. Approximately 70% of Al and B were leached as well, while other elements (Co, Ni, Cu) had leaching efficiencies below 40%, leaving a hematite rich residue. Adjusting the pH removes Al and Fe in leachate but minimally affects Cu, Co, and Ni. Na2S addition is more effective against transition metals, but both methods result in around 10% REEs loss. Direct oxalate precipitation is suggested for the obtained leachate, which can yield over 97.5% REEs oxides with approximately 1.0% alumina, which is acceptable for magnet remanufacturing due to the aluminum content commonly found in magnets. The technology developed in this study offers opportunities for closed-loop recycling and remanufacturing of PMs, benefiting the environment, economy, and supply chain security.