Advances in Dysprosium Recovery from Secondary Sources: A Review of Hydrometallurgical, Biohydrometallurgical and Solvometallurgical Approaches

Dysprosium is one of the most critical elements for global economies due to its essential role in the green energy transition. Although it is added in small quantities as an alloying element, dysprosium plays a crucial role in NdFeB magnets used in wind turbines and industrial motors. On the other hand, the limited resources and production capacity of dysprosium contribute to supply shortages and raise concerns about its long-term availability. Therefore, there is a need for efficient techniques that will enable the recovery of dysprosium from secondary materials to bridge the gap between supply and demand while addressing the risks associated with securing a stable supply. This review focuses on (bio)hydrometallurgical and solvometallurgical methods for recovering dysprosium from key secondary sources such as spent NdFeB magnets, phosphogypsum, and coal ash. Although these wastes do not always contain high concentrations of dysprosium, they can have a simpler elemental composition compared to primary sources (a few tens or hundreds of ppm Dy) and are more readily available. Spent NdFeB magnets, with a few percent Dy, show the most promise for recycling. In contrast, coal fly ashes (with several ppm Dy), although widely available, bind dysprosium in an inert phase, requiring substantial pretreatment to enhance the release of the desired element. Phosphogypsum, while not yet a significant source of dysprosium (several ppm Dy), is increasingly recognized as a potential source for other rare earth elements. Although conventional hydrometallurgical methods are commonly used, these are typically unselective for dysprosium recovery, whereas unconventional solvometallurgical approaches show preferential extraction of dysprosium over base metals.