NdFeB magnets are used in wind turbines and hybrid electric vehicles and are instrumental in progression toward a low-carbon economy. Recycling rare-earth elements (REEs) from NdFeB magnet waste is an important step toward building a sustainable REE supply chain. In this study, we describe an electrochemical process to selectively extract REEs from NdFeB magnet waste at room temperature. First, an electrolysis pretreatment step was performed to convert the elements present in the magnet waste into the respective hydroxides. A dual anode system was used where NdFeB magnet waste was taken as an anode along with an inert anode in an electrochemical reactor. The inert anode was used to ensure that iron in the magnet waste was converted into the Fe(III) form in the mixed hydroxides precipitate. Subsequently, the mixed hydroxides were leached with HCl. More than 97% of REEs and cobalt leached into the solution leaving iron in the residue. REEs were then selectively precipitated as rare-earth oxalates using oxalic acid, which in turn regenerated HCl, resulting in a closed-loop process. Calcination of the rare-earth oxalates yielded rare-earth oxides of high purity (99.2%), which can be used directly for producing rare-earth metals.

The dissolution of rare earth oxides in molten fluorides is a critical step in the preparation of the corresponding rare earth metals by oxide-fluoride electrolysis. However, quantitatively understanding the nature of dissolution, especially in the case of molten salts, is usually difficult to be achieved by postmortem characterization. In this paper, the dissolution behavior of Nd₂O₃ particles in molten fluorides was studied via in situ observation with confocal scanning laser microscopy. Combining direct observation with thermodynamic analyses on the oxide dissolution, the rate-limiting step(s) and the effects of parameters like temperature, salt type, and composition on the dissolution rate are identified. This study provides a methodology to estimate the dissolution kinetics of rare earth oxides in molten fluorides during their primary and secondary processing.

The analytical and numerical description of the effective dissolution kinetics of spherical particles into a solvent is often difficult in chemical and metallurgical engineering. The crucial first step is to identify the dissolution mechanisms, and subsequently, relevant kinetics parameters can be calculated. In this article, three frequently used approximations, i.e., the invariant-field (IF) (Laplace), reverse-growth (RG), and invariant-size (IS) (stationary-interface) approximations, are systematically discussed and compared with numerical simulation results. The relative errors of the dissolution curves and total dissolution time of the three approximations to the numerical simulations are calculated. The results reveal the appropriate application ranges of the approximations for given precision levels. With further experimental validation, this research provides a methodology to properly assess dissolution kinetics and adequately estimate effective diffusion coefficients and activation energy under the experimental uncertainties.