Hydrometallurgical Recovery Technology for Rare Earth and Iron Separation from Spent NdFeB Magnets

The recovery of rare earth elements (REEs) from the spent NdFeB magnets has great strategic significance for ensuring the security of critical mineral resources. This process requires scientifically designed separation technologies to ensure high output and purity of the obtained rare earths. Hydrometallurgy has been widely applied to extract REEs from spent permanent magnets. This paper summarizes and reviews hydrometallurgical technologies, mechanisms, and applications for the separation and recovery of REEs and iron (Fe) from the spent permanent magnets. Key methods include: The hydrochloric acid total solution method, where the spent NdFeB is completely dissolved in hydrochloric acid, iron is precipitated and removed, and then REEs are extracted. The hydrochloric acid preferential dissolution method, where spent NdFeB magnets are first fully oxidized by oxidative roasting, converting Fe2+ to Fe3+, which hydrolyzes to Fe(OH)3, and is precipitated and removed, allowing for the subsequent extraction of REEs to obtain rare earth oxides. Acid baking and water leaching, where spent NdFeB is calcined with acidification reagents, and the calcined products are dissolved in water to leach out REEs. At the same time, Fe is retained in the leaching residue. Electrolysis in aqueous solution, where Fe is electrolyzed at the anode or deposited at the cathode to separate it from REES. Organic acids leaching, where organic acids dissolve metals through acidolysis and complexation. Bioleaching, which utilizes microorganisms to recover metal through biological oxidation and complexation. Ionic liquid systems, where Fe or REEs are extracted using ionic liquid or leached by deep eutectic solvents. This paper provides an in-depth discussion on the challenges, advantages, and disadvantages of these strategies for recycling spent NdFeB magnets, as well as the leaching and extraction behavior of REEs. It focuses on environmental impact assessment, improving recovery efficiency, and decreasing reagent consumption. The future development direction for recycling spent NdFeB magnets is proposed, and a research idea of proposing a combined process to avoid the drawbacks of a single recycling method is introduced.