Milling-Assisted Leaching for Mercury Stabilization and Material Recovery from End-of-Life Fluorescent Lamps

The disposal of end-of-life fluorescent lamps presents significant environmental challenges due to their mercury (Hg) content and the loss of valuable rare earth elements (REEs) contained in phosphor powders, highlighting the need for sustainable recycling strategies. This study proposes an integrated hydrometallurgical process for simultaneous mercury removal and material recovery from spent fluorescent lamps. Various leaching agents were initially evaluated for mercury dissolution, and 10% NaOCl was identified as the most effective solution. The optimized system was applied to linear T8 lamps using a combined milling–leaching approach, followed by size-based separation of metallic, glass, and phosphor fractions. Dissolved mercury was precipitated at pH 11 using Na2S, forming crystalline α-HgS (cinnabar), as confirmed by XRD, and reducing the residual mercury concentration to 2.7 µg/L. The metallic fraction was recovered as an aluminum-based alloy containing 20.6 wt.% Cu and 10.9 wt.% Zn with low iron content, while the phosphor-rich fraction yielded approximately 50% REE extraction, followed by oxalate precipitation of yttrium-based compounds. The developed process enables efficient mercury stabilization and selective recovery of valuable materials, supporting environmentally secure and resource-efficient fluorescent lamp recycling.