Study of the kinetics and mechanisms of rare earth elements leaching from end-of-life NdFeB magnets through Hydro-Nd process

With the growing demand for REEs in numerous high-tech and energy transition-related applications, recycling these elements from secondary sources, mainly from end-of-life permanent magnets, has become crucial for responsible sourcing of raw materials from a circular economy. To date, numerous processes have been developed and optimized to allow this recovery to be sustainable from both an economic and environmental point of view. In this context, hydrometallurgy is one of the most promising avenues. Through an innovative hydrometallurgical process (Hydro-Nd), this research investigated the kinetics and mechanisms involved in leaching REEs from end-of-life permanent magnets. This process involves the use of citric acid in the leaching phase. Through systematic experimentation and analysis, the article elucidates key factors influencing leaching kinetics, providing insight into critical mechanisms of the process. In particular, ANOVA was used to study the influence of important factors (temperature, particle size, and agitation) on the recovery yields of the elements of interest. The shrinking core model studied the leaching mechanisms to identify a possible rate-determining step. Thanks to the results obtained, the Arrhenius parameters were estimated for the different heterogeneous reactions involved in the process, and the trend of the time constants versus the average diameter of the solid particles was identified. Also, the results showed that 100 % of Nd, Fe, Dy, B, and Pr from small PM particles (0–40 µm) in 4 h and more than 90 % of the mentioned metals from large particles (1000–1700 µm) within 5 h of leaching time were dissolved by citric acid solution. This research not only contributes to the development of an even more sustainable rare earth recovery process thanks to the optimization of several factors but also clarifies fundamental aspects of leaching kinetics and mechanisms, paving the way for future advances in the recovery of REEs from different sources.