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Selective Extraction of Rare Earth Elements from Permanent Magnet


Scraps with Membrane Solvent Extraction
Daejin Kim,† Lawrence E. Powell,† Lætitia H. Delmau,‡ Eric S. Peterson,§ Jim Herchenroeder,∥
and Ramesh R. Bhave*

Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, Tennessee 37831, United States

Nuclear Materials Processing Group, Oak Ridge National Laboratory, Oak Ridge, Tennessee 37831, United States
§
Center for Advanced Energy Studies, Idaho National Laboratory, Idaho Falls, Idaho 83415, United States

Molycorp Magnequench, Greenwood Village, Colorado 80111, United States
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*
S Supporting Information
Downloaded via IOWA STATE UNIV on January 15, 2019 at 15:56:38 (UTC).

ABSTRACT: The rare earth elements (REEs) such as


neodymium, praseodymium, and dysprosium were successfully
recovered from commercial NdFeB magnets and industrial
scrap magnets via membrane assisted solvent extraction
(MSX). A hollow fiber membrane system was evaluated to
extract REEs in a single step with the feed and strip solutions
circulating continuously through the MSX system. The effects
of several experimental variables on REE extraction such as
flow rate, concentration of REEs in the feed solution,
membrane configuration, and composition of acids were
investigated with the MSX system. A multimembrane module
configuration with REEs dissolved in aqueous nitric acid
solutions showed high selectivity for REE extraction with no coextraction of non-REEs, whereas the use of aqueous hydrochloric
acid solution resulted in coextraction of non-REEs due to the formation of chloroanions of non-REEs. The REE oxides were
recovered from the strip solution through precipitation, drying, and annealing steps. The resulting REE oxides were characterized
with XRD, SEM-EDX, and ICP-OES, demonstrating that the membrane assisted solvent extraction is capable of selectively
recovering pure REEs from the industrial scrap magnets.

■ INTRODUCTION
The world today has hugely benefited from the application of
from NdFeB permanent magnets used in automobiles, mobile
phones, hard disk drives, computers, tablets, electric motors,
and hybrid electric vehicles; (2) europium (Eu), terbium (Tb),
rare earth elements (REEs) to most high-tech devices such as
and yttrium (Y) from phosphors in fluorescent lamps, LEDs,
cell phones, rechargeable batteries, computers, TV, and
LCD backlights, and plasma screens; and (3) lanthanum (La),
fluorescent lighting.1−3 These REEs are the 15 lanthanides in
cerium (Ce), Nd, and Pr from nickel metal hydride batteries in
the periodic table along with scandium and yttrium. Over 90%
rechargeable batteries, and hybrid electric vehicle batteries.9
of REEs worldwide are currently being produced in China Even though there are a variety of end-of-life products available
which until very recently had restricted REE exports. The rising for REE recovery, the actual REE recovery is currently
REE demand in high-tech devices over the past two decades estimated to be less than 1% due to low efficiencies and
resulted in skyrocketing prices of REEs in just a few years.4−7 limitations in recycling processes.10 Therefore, it is pivotal to
This motivated the U.S. Department of Energy to launch the develop and improve the effective REE recycling process in
Critical Materials Institute in 2013 in order to tackle the REE order to widen the reuse of REE-containing end-of-life
supply challenge, focusing on three different areas such as products.
diversifying REE supplies, developing REE substitutes, and Even though commercial REE recycling is presently very
recycling REE wastes.8 Among those approaches, this study limited, the REEs can be recovered through several processing
focuses on the recovery and recycling of end-of-life REE technologies such as hydrometallurgy, pyrometallurgy, and gas-
products. When compared to REE mining processes, recycling
of REEs from postconsumer products provides significant
Special Issue: Critical Materials Recovery from Solutions and Wastes
environmental benefits with regard to air emissions, ground-
water contamination, soil acidification, eutrophication, and Received: March 25, 2015
climate change.2 Revised: June 22, 2015
The recoverable REEs from end-of-life products are (1) Accepted: June 24, 2015
neodymium (Nd), dysprosium (Dy), and praseodymium (Pr) Published: June 24, 2015

© 2015 American Chemical Society 9452 DOI: 10.1021/acs.est.5b01306


Environ. Sci. Technol. 2015, 49, 9452−9459
Environmental Science & Technology Article

phase extraction. Hydrometallurgy uses strong acid to dissolve characterized by X-ray diffraction (XRD), energy-dispersive X-
REE-containing end-of-life products and then uses basic ray spectroscopy (EDX), and inductively coupled plasma-
solutions to selectively precipitate the REEs of interest. This optical emission spectroscopy (ICP-OES).
process includes solvent extraction, leaching, and precipitation.
However, this process requires high chemical usage and suffers
from generation of large amounts of chemical waste and low
■ EXPERIMENTAL SECTION
The distribution coefficient of neodymium was determined by
selectivity due to coextraction of non-REEs.9 The pyrometallur- mixing organic phase with the REE-containing aqueous
gical process utilizes high temperatures to chemically convert solution for 2 h, followed by separating aqueous phase from
feed materials into the valuable REEs. This process requires organic phase. The organic phase is composed of extractants
fewer processing steps than the hydrometallurgical route, but it (TODGA (Marshallton Research) or Cyanex 923 (CYTEC
requires larger energy input and generates larger amounts of Industries Inc.)), tributyl phosphate (TBP, Stauffer Chemical
solid waste.9,11 The REE recovery by gas phase extraction route Company) as another extractant, and Isopar L (Isoparaffin,
is based on volatility differences, involving chlorination and ExxonMobil Chemical) as solvent. The aqueous phase was
carbochlorination, but corrosive aluminum chloride and prepared by dissolving permanent magnets, neodymium(Nd)-
hydrogen chloride gas generated from this process pose serious iron(Fe)-boron(B) magnets (K&J Magnetics, grade D42) in
environmental and safety hazards.12,13 1−6 M HNO3 and 3−6 M HCl. The concentration of REEs in
Membrane assisted solvent extraction (MSX) can provide the organic phase was back-calculated from the REE
another alternative to recover REEs, eliminating the disadvan- concentration in the aqueous phase measured by ICP-OES
tages of traditional equilibrium-based solvent extraction (IRIS Intrepid II XSP, Thermo Electron Corporation).
processes such as loading, flooding, and third phase Hydrophobic membranes are desirable for the extraction of
formation.14,15 In the continuous operation mode, separation REEs because hydrophobicity prevents wetting of the
in MSX is enhanced under nonequilibrium conditions due to membrane by aqueous feed solution and also prevents the
the maintenance of high driving forces over extended periods of displacement of organic phase immobilized in the pores into
time compared to equilibrium limited conventional solvent the strip solution. For this reason, hydrophobic polypropylene
extraction. While the solvent extraction process carries out membrane modules (MicroModule, Membrana, area 100 cm2,
extraction and stripping in two separate steps, MSX combines ID: 0.25 mm, number of hollow fibers: 700) were used as
both processes in a single step, circulating the feed and strip membrane supports. The REE sources for the feed solution
solutions continuously without dispersion of different were chosen from three different NdFeB magnets; commercial
phases.16,17 Utilizing hollow fiber membrane modules in the NdFeB magnets from (1) K&J Magnetics (Grade D42) and
MSX system provides high contact surface area per unit volume industrial scrap magnets from (2) Molycorp Magnequench
to achieve a high REE extraction rate. In the MSX system, an (Harrodsburg, KY) and (3) Daido Electronics Co. Ltd. (Japan).
organic phase consisting of extractant and organic solvent is The composition of the magnets is shown in Table S1
immobilized in the pores of hollow fiber membranes, and the (Supporting Information). These magnets were dissolved in
aqueous feed and strip solutions flow through the lumen and concentrated nitric acid or hydrochloric acid for 24 h.
shell side of hollow fiber modules, respectively, as shown in Using the commercial NdFeB magnets, the membrane
Figure S1 (Supporting Information). The organic solvent is assisted solvent extraction was carried out with 2 L feed
immiscible with very low solubility in aqueous solution which solution containing approximately 1000 and 2000 ppm of Nd
minimizes extractant and solvent losses. and the strip solution of 0.23 or 0.5 L. The molar
Acidic extractants are widely used in current industrial concenstration of HNO3 in the feed solution was 6 M and
practice, but they suffer from relatively low REE selectivity due the strip solution was 0.2 M HNO3. The pores of hollow fibers
to simultaneous coextraction of other cations such as Fe, Cu, in the membrane modules were filled with organic phase
and Ni.18,19 On the contrary, neutral extractants such as consisting of the TODGA, Isopar L, and TBP in the ratio of
tetraoctyl diglycol amide (TODGA) and trialkyl phosphine 3:4:3, respectively. The shell side of hollow fibers was supplied
oxides (Cyanex 923) have shown the capability of selectively with the aqueous strip solution, and the lumen side of the
extracting several lanthanides and actinides such as cerium, hollow fibers was fed with the feed solution containing REEs.
europium, uranium, and cesium.20−22 Therefore, we have Both the feed and strip solutions were simultaneously circulated
utilized neutral extractants, TODGA and Cyanex 923 in this throughout the MSX system with peristaltic pumps. The feed
work. They were evaluated to selectively extract REEs from solution was thoroughly mixed with a mixer (Talboys,
permanent magnets in the presence of non-REEs such as Fe, B TROEMNER, LLC) to maintain uniform concentration. The
and other transition metals (Cu, Ni) used in the outer coating. pressure on the feed side was maintained at 15 psig and the
The distribution coefficient (D) is the ratio of REE strip side was kept at atmospheric pressure. The flow rate of the
concentration in the organic phase to that in the aqueous feed solution varied from 35 to 105 mL/min to investigate the
phase at equilibrium. D values of neodymium extracted by effect of flow rate on REE recovery. For ICP analysis, ∼5 mL
TODGA and Cyanex 923 were first measured to determine samples were collected from both feed and strip solutions over
their relative efficiencies prior to incorporating them in the the duration of the experiment. The effect of membrane
membrane supports. The effects of the concentration and flow configuration on REE extraction was studied by connecting 8-
rate of the feed solution, membrane configuration, and acid membrane modules in series and parallel (Figure S2,
composition on REE extraction were then systematically Supporting Information). Experiments with 3 and 6 M
investigated using commercial NdFeB magnets. The MSX hydrochloric acid were also conducted to study the effect of
system was also utilized to extract REEs from industrial scrap acid composition on REE extraction. 0.2 M HCl solution was
magnets. The REEs in the scrap magnets were recovered from used as the strip on shell side of the module.
the strip solution in the MSX system by precipitating, filtration, Upon the optimization of experimental conditions with the
drying, and annealing steps. The resulting REE oxides were commercial NdFeB magnets, the two industrial scrap magnets
9453 DOI: 10.1021/acs.est.5b01306
Environ. Sci. Technol. 2015, 49, 9452−9459
Environmental Science & Technology Article

Figure 1. Distribution coefficient of Nd from NdFeB magnets (D42) with TODGA and Cyanex 923 in (a) HNO3 and (b) HCl.

Figure 2. (a) The elemental concentration of NdFeB magnets in the (a) feed and (b) strip solutions while running the 8-module system in parallel,
(c) the ratio of REEs in the strip to the feed and (d) REE extraction rate (feed: 6 M HNO3, ∼1000 ppm of Nd, strip: 0.2 M HNO3, 0.23 L).

procured from Molycorp Magnequench and Daido Electronics concentration on the distribution coefficient was only
were utilized to recover REEs with the MSX system. The considered in this study.23 Figure 1 shows distribution
extracted REEs in the strip solution from those scrap magnets coefficients of neodymium from NdFeB magnets (D42)
were precipitated out with oxalic acid, followed by filtration, obtained with TODGA and Cyanex 923 in aqueous HNO3
drying at room temperature, and annealing at 750 °C for 2 h. and HCl solutions. As shown in Figure 1, distribution
The resulting REE oxides were characterized by X-ray coefficient of Nd extracted by TODGA was substantially
diffraction (XRD), energy-dispersive X-ray spectroscopy greater than that obtained with Cyanex 923 at several different
(EDX, HITACHI S-4800). The recovered REEs were representative acid concentrations. High D values with
redissolved in nitric acids to evaluate the purity of REE oxides TODGA can be attributed to strong oxygen donor atoms in
with ICP-OES (IRIS Intrepid II XSP, Thermo Electron TODGA, whereas low D values on Cyanex 923 are likely due to
Corporation). the low adsorption ability of Cyanex 923 for the REEs.24,25 This

■ RESULTS AND DISCUSSION


The critical requirement in the extraction of REEs with the
result confirms that TODGA is more suitable than Cyanex 923
for extraction of REEs from NdFeB magnets. Thus, TODGA
was chosen as the preferred extractant in the MSX system to
MSX system is the incorporation of a selective extractant in extract REEs from the permanent magnets in this research.
organic phase by impregnation in the pores of hollow fiber There are several process variables that can have an effect on
support. We have evaluated two different neutral extractants, REE recovery in the MSX system, such as REE concentration,
TODGA and Cyanex 923. These were first evaluated to molar concentration of acid, and membrane area. These
determine the distribution coefficient of neodymium at various variables were investigated in a prior study.26 The molar
acid concentrations. Although the distribution coefficient is a concentration of HNO3 in the feed and strip was chosen as 6 M
function of temperature, pH, metal ion concentration, and 0.2 M, respectively. This was based on favorable values of
extractant and solvent concentration, the effect of molar acid distribution coefficient at high acid concentration. The 8-
9454 DOI: 10.1021/acs.est.5b01306
Environ. Sci. Technol. 2015, 49, 9452−9459
Environmental Science & Technology Article

Figure 3. Elemental concentration of NdFeB magnets in the (a) feed and (b) strip solutions, and (c) the ratio of REEs in the strip to the feed and
(d) REE extraction rate while running the 8-module system in series for 96 h (feed: 6 M HNO3, 2L; strip: 0.2 M HNO3, 0.5 L).

membrane module system was used to extract REEs. Another accumulation of particulate matter. However, in order to
experimental variable that can impact REE extraction is the feed maintain the desired concentration of extractants in the
flow rate. The flow rate of the feed side in the 8-membrane membrane pores, the organic phase might need to be
modules was varied from 35 to 105 mL/min, while keeping all supplemented periodically to achieve long-term stability
other experimental conditions constant. Figure S3 (Supporting (>1000 h). The expected frequency of replenishing extractants
Information) shows the effect of flow rate of the feed solution would be once every couple of months.
on REE recovery in the MSX system. As can be seen in Figures S4(a) and (b) (Supporting Information) show the
Supporting Information Figure S3, the ratio of REE elemental concentration of NdFeB magnets in the feed and
concentration in the strip to the feed only slightly decreased strip solutions when the feed concentration was doubled from
as the feed flow rate increased, suggesting that the extraction ∼1000 ppm to ∼2000 ppm of Nd, while maintaining all other
rate is not significantly impacted by the feed flow rate. conditions as shown in Figure 2. It can be seen from
Therefore, a feed flow rate of 35 mL/min was selected in the Supporting Information Figure S4(b) that Nd, Dy and Pr
MSX system for the rest of this study. were selectively recovered with no coextraction of non-REEs
The 8-membrane modules were connected in parallel to such as Fe and B. The other non-REEs such as Cu and Ni used
enable the feed solution to be evenly distributed into each in the outer coating of the magnets were also undetectable by
membrane module, as shown in the schematic of Figure S2 (a) ICP-OES. This high selectivity of REEs over non-REEs could
(Supporting Information). Figure 2 shows the elemental be attributed to the nonequilibrium separation process of
composition of (a) the feed (commercial NdFeB magnets membrane assisted solvent extraction. In this case, REEs are
(K&J Magnetics, grade D42)) and (b) the strip solutions while continuously extracted at high driving forces without
operating the 8-membrane module system for 55 h. The molar approaching equilibrium where coextraction can occur.
concentration of nitric acid in the feed and the strip was 6 M However, as shown in Figure S4(c) (Supporting Information),
and 0.2 M, respectively. At around 24 h from the start, Nd the recovery of Nd and Pr with higher concentration of feed
concentration in the strip was about 900 ppm and then solution (∼2000 ppm of Nd) decreased by about 50%,
decreased slowly as operating time increased, whereas Pr indicating that REE extraction through the membrane is not
concentration kept increasing over 55 h. As shown in Figure 2 limited by concentration gradient, but by the amount of
(c), the Nd concentration ratio in the strip to the feed was >1.0 available extractants in the hollow fiber pores. Figure S5
after a run time of 20 h, and the concentration of Pr in the strip (Supporting Information) shows the extraction results while
increased up to 95% of the initial Pr concentration in the feed. running the 8-membrane module system for 96 h with
Figure 2 (d) shows extraction rates of Nd and Pr while running increased strip volume (0.5 L). All other conditions were
the 8-membrane module system. In both cases, the REE identical to those reported for Supporting Information Figure
extraction rates rapidly declined at the beginning of the run S4. The behavior of the Nd, Pr, Dy recovery over time with the
even at high REE concentration, indicating that REE extraction higher strip volume was very similar to that of REEs with the
may be significantly limited by the amount of extractants strip volume of 0.23 L (see Figure S4, Supporting Information).
available in the pores of hollow fibers. Typically, MSX system A small increase in the extraction rate was observed with the
does not experience any fouling issue often caused by the higher strip volume in Supporting Information Figure S5(d)
9455 DOI: 10.1021/acs.est.5b01306
Environ. Sci. Technol. 2015, 49, 9452−9459
Environmental Science & Technology Article

Figure 4. Elemental concentration of NdFeB magnets in the (a) feed and (b) strip solutions, and (c) the ratio of REEs in the strip to the feed and
(d) REE extraction rate while running the 8-module system in series for 96 h (feed: 6 M HCl, 2L; strip: 0.2 M HCl, 0.5 L).

Figure 5. Elemental concentration of scrap magnets (Molycorp Magnequench) in the (a) feed and (b) strip solutions, and (c) the ratio of REEs in
the strip to the feed and (d) REE extraction rate while running the 8-module system in series for 100 h (feed: 6 M HNO3, 2L; strip: 0.2 M HNO3,
0.5 L).

compared to the lower strip volume (0.23 L) in Supporting 3(a) and (b) show the concentration of NdFeB magnet
Information Figure S4(d). elements in the (a) feed and (b) strip solutions while running
In order to evaluate the influence of membrane module the 8-module system in series for 96 h. The ratio of REE
configuration on REE extraction, the 8-membrane modules concentrations in the strip to the feed solution and REE
were connected in series as shown in Supporting Information extraction rates with the 8-modules in series configuration are
Figure S2(b). All other extraction conditions were identical to shown in Figure 3(c) and (d). The Nd and Pr recoveries with
those reported in Supporting Information Figure S5. Figure the 8-membrane modules connected in series were about 20%
9456 DOI: 10.1021/acs.est.5b01306
Environ. Sci. Technol. 2015, 49, 9452−9459
Environmental Science & Technology Article

Figure 6. SEM-EDX analysis of REEs recovered from Magnequench scrap magnets by membrane assisted solvent extraction.

higher than that with the 8- modules in parallel. In addition, the practice, it would be more desirable to use HNO3 in the MSX
extraction rate for the first 24 h run time was almost double to system to recover high purity REEs from the Nd-based
that observed for the 8-modules connected in parallel. These magnets, based on the results obtained in this study. However,
results confirm that the membrane configuration in series utilizing ionic liquids, such as trihexyl(tetradecyl)phosphonium
shows better REE extraction performance than the config- chloride, which has shown high distribution ratio for iron over
uration where modules are connected in parallel. REEs in HCl, may be an option to post-treat the HCl based
The use of hydrochloric acid instead of nitric acid for REE strip solution to recover pure REEs.28
extraction was evaluated in the MSX system as it is generally Upon the optimization of the MSX system performance with
the preferred acid in many traditional precipitation and commercial NdFeB magnets, the REE recovery from industrial
extraction technologies for REE recovery. Figure 4(a) and scrap magnets with membrane assisted solvent extraction was
(b) show the elemental concentration in the feed and strip investigated. The end-of-life scrap magnets were procured from
solutions while operating the 8-membrane module system Molycorp Magnequench, which contains about 30 wt % REEs
connected in series with 6 M HCl in the feed and 0.2 M HCl in (see Supporting Information Table S1). Figure 5 (a) shows the
the strip. Figure 4(c) and (d) show the ratio of REE elemental concentration of the Magnequench scrap magnet
concentration in the strip to the feed and REE extraction dissolved in 6 M HNO3. The elemental concentrations in the
rate, respectively. As shown in Figure 4(b) and (c), significant strip solution and the ratio of REEs in the strip to the feed
amounts of Fe and B were coextracted with REEs into the strip while operating the 8-membrane module system are shown in
solution. The ratio of Fe concentration in the strip to the feed Figure 5(b) and (c), respectively. The results show that only
in 48 h was about 1.6 which is much higher than that of Nd and REEs such as Nd, Pr, and Dy were selectively extracted from
Pr in Figure 4(c). The coextraction of REEs could be attributed the scrap magnets into the strip solution with the MSX system,
to the formation of tetrachloroanions of non-REEs in the without any coextraction of non-REEs such as Fe and B. Figure
presence of HCl as described below.27 This mechanism is not S7 (Supporting Information) shows the REE extraction results
applicable as nitrate anions are not formed that can be obtained with the industrial scrap magnets procured from
coextracted when nitric acid is used for REE extraction. Daido Electronics. As shown in Supporting Information Figure
2Fe + 6HCl → 2FeCl3 + 3H 2 S7(b) and (c), only REEs were selectively recovered from
Daido Electronics scrap magnets with the MSX system, and
there was no coextraction of non-REEs in the strip solution
TODGA + FeCl3 + HCl ↔ TODGA·H+·FeCl−4
over the 120 h run. These results clearly demonstrate that
membrane assisted solvent extraction is capable of selectively
3TODGA·H+·FeCl−4 + Nd3 + + 3Cl− recovering REEs from industrial scrap magnets.
↔ [(TODGA)3 Nd]3 + (FeCl−4 )3 + 3HCl The REEs extracted into the strip solution from the scrap
magnets were then precipitated with oxalic acid, followed by
Figure S6(a) and (b) (Supporting Information) show the filtration, drying, and annealing steps. Figure S8 (Supporting
elemental concentration in the feed and strip when 3 M HCl Information) shows the XRD patterns of resulting REE oxides
was used in the feed solution with the 8-membrane modules to recovered from the scrap magnets procured from Molycorp
extract REEs from permanent Nd-based magnets. As shown in Magnequench. The majority of peaks shown in the XRD
Figure S6(b) and (c) (Supporting Information), even though analysis correspond to the peaks for REE oxides such as Nd2O3
the ratio of Nd and Pr in the strip to the feed was significantly (JCPDS 21−0579) and PrO1.83 (JCPDS 06−0329), indicating
higher compared to that with 6 M HCl in the feed, the that REE oxides were successfully recovered from industrial
coextraction of Fe was still observed resulting in high scrap magnets via the MSX system. The purity of recovered
concentration of Fe in the strip, unlike when HNO3 was REEs was examined by SEM-EDX analysis, as shown in Figure
used in the aqueous solutions. As can be seen from these 6. There is no indication of the presence of iron in the
results, although HCl is widely used in current industrial recovered REE oxides based on the EDX analysis. In addition,
9457 DOI: 10.1021/acs.est.5b01306
Environ. Sci. Technol. 2015, 49, 9452−9459
Environmental Science & Technology Article

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Corresponding Author enhancement of the extraction of trivalent lanthanides and actinides by
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