Comparative Study of Manufacturing NdFeB Magnet Wastes Recycling: Oxidative Roasting-Selective Leaching and Whole Leaching Routes

This research investigated recycling of manufacturing NdFeB magnet wastes in as-sintered and powder forms which contained high carbon via pyro-hydro metallurgy process. Effects of oxidative roasting on selective leaching of the magnet wastes were the main focus in comparison to recycling via whole leaching without oxidative roasting. The process started from oxidative roasting at 600 °C, sulfuric leaching, drying, roasting at 750 °C for powder and 800 °C for sintered wastes, water leaching, oxalic acid precipitation and calcination at 1000 °C to obtain neodymium oxides. Oxidative roasting was found to reduce carbon and resulted in neodymium and iron oxide formation with a minimum amount of neodymium iron oxide. This provided effective selective leaching of neodymium. For whole leaching, a significant loss of neodymium into leached residue was observed. Oxidative roasting-selective leaching provided significant recovery in the amount of 75.46% while whole leaching resulted in only 31.62 wt.% in the case of sintered waste. The final composition via oxidative roasting-selective leaching consisted of 68.11 wt.% neodymium, 19.83 wt.% praseodymium and 0.31 wt.% iron, while whole leaching resulted in a higher amount of iron at 1.20 wt.%. Similar results were obtained for powder magnet waste