Pyrometallurgical Recovery of Neodymium from Nd–Fe–B Magnets in End-of-Life Electric Vehicle Motors Using Non-Ferrous Smelting Slag Flux

The increasing use of electric vehicles has led to a growing demand for rare-earth elements, particularly neodymium (Nd), which is a critical component of Nd–Fe–B permanent magnets used in traction motors. End-of-life electric vehicle motors are therefore considered promising secondary resources for Nd recovery. In this study, a pyrometallurgical process using non-ferrous smelting slag as a flux was proposed for recovering Nd from Nd–Fe–B magnets contained in waste electric vehicle motors. Steel and magnet fractions obtained from a dismantled motor were melted at approximately 1600 °C under an air atmosphere, and Fe2O3 was added as an oxidizing agent to promote the selective oxidation of Nd. The oxidized Nd was subsequently partitioned into the slag phase as Nd2O3 through metal–slag separation. The effects of the slag flux addition ratio, Fe2O3 content, slag flux type, and crucible material on Nd recovery behavior were systematically investigated. Increasing the fayalite-based slag flux addition enhanced Nd transfer into the slag phase, and the highest Nd recovery of approximately 80% was obtained at a slag flux addition ratio of 30 wt%. The addition of 2 wt% Fe2O3 was found to be suitable for promoting stable Nd oxidation and efficient slag–metal separation. The non-ferrous smelting slag exhibited chemical and phase characteristics comparable to those of synthetic fayalite slag flux, resulting in similar Nd recovery performance. In addition, the crucible material significantly affected the process stability and Nd recovery behavior. Although a carbon crucible showed relatively high Nd recovery, severe slag foaming and crucible erosion occurred during melting. In contrast, alumina and MgO crucibles provided stable process conditions with comparable Nd recovery behavior, whereas zirconia crucibles caused relatively higher Nd loss. These results demonstrate that non-ferrous smelting slag can be effectively used as a flux for the pyrometallurgical recovery of Nd from end-of-life electric vehicle motors, offering a potential route for sustainable rare-earth recycling.