Selective Recovery of Rare Earth Elements from Electric Motors in End-of-Life Vehicles via Copper Slag for Sustainability

Discarded NdFeB permanent magnets will become a significant source of rare earth elements (REEs) in the future. Electric vehicle (EV) motors utilize 2–5 kg of NdFeB magnets, and researchers are prioritizing the development of suitable extraction technologies. The objective of our research is to separate metal materials (Al, Cu, Fe and FEEs) from EV motors, based on their melting temperatures. REE magnets that pose the greatest challenge are melted together with the electrical steel of the motor, and the potential for extracting REEs in a selective manner from the molten steel was examined based on their significant oxidation potential using FeO–SiO2 compounds, which act as an oxidizing slag-forming agent, to test the extraction method. Fayalite (2FeO·SiO2) is the most easily created and ideal eutectic compound for carrying oxygen (FeO) and forming slag (SiO44−), typically generated during copper smelting. In this experiment, copper slag was used and the results were compared to a smelting test, which had previously used a synthesized fayalite flux as a model. The smelting test, utilizing synthesized fayalite flux, yielded a 91% Nd recovery rate. The Nd recovery rate in the smelting test with copper slag hit a high of 64.81%, influenced by the smelting’s holding time. The steel contained 0.08% Nd. Iron was recovered from the copper slag at a rate of 73%. During the smelting test, it was observed that the reaction between Nd2O3 and the Al2O3 crucible resulted in the formation of a layer on the surface of the crucible, diffusion into the crucible itself, and a subsequent reduction in the efficiency of Nd recovery.