Recovery of iron as hematite and separation of trivalent lanthanide ions from spent hard disk magnet leach liquor...

The widespread use of neodymium-iron-boron (NdFeB) magnets has raised concerns about the environmental impact of their disposal, prompting the need for sustainable recycling strategies. Traditional solvents used in recycling are toxic and flammable, making them risky to use. Ionic liquids are safer and greener options with low vapor pressure, high stability, and less flammability. This study introduces an eco-friendly recycling approach utilizing the [P66614][Cy272] ionic liquid to selectively extract iron and recover rare earth elements (REEs) from the leach liquor of waste NdFeB magnets. Pre-treatment processes enhanced metal concentration before leaching, including demagnetization, grinding, and screening. Optimal leaching conditions: 2 mol L^-1 HCl, 80 °C, 10 g L^-1 pulp density, and 90 minutes, resulted in complete leaching of REEs (Dy, Pr, Nd), iron, and boron. Using 0.01 mol L^-1 [P66614][Cy272] ionic liquid, 100% of the iron was removed from the leach liquor with minimal co-extraction of REEs (∼4%). Precipitation of iron leading to Fe₂O₃ (hematite) after calcination and is verified through XRD and SEM-EDS analyses. The ionic liquid also enabled 81.1% recovery of HCl from the leach liquor, reducing neutralization needs and operational costs. Subsequent REEs separation using 0.01 mol L^-1 [P66614][Cy272] ionic liquid demonstrated high selectivity, achieving separation factors of 18.55 (Dy/Pr) and 15.52 (Dy/Nd) at pH 2.03. Dy(iii) was successfully separated from NdFeB leach solutions using counter-current extraction, leaving 6.0 mg L^-1 in the raffinate, requiring two extraction stages at a 2 : 3 organic-to-aqueous phase (O/A) ratio. The reusability of the ionic liquid further enabled a sustainable, closed-loop recycling process. This approach highlights the potential for integrating ionic liquids into green technologies for NdFeB magnet recycling, ensuring resource recovery while minimizing environmental impact.