Neodymium Extraction from Spent Magnet Using Molten Salt: Thermodynamic Assessment for Suitable Mixed-Chlorides System
摘要
The rising demand for rare earthRare earth elements (REEs), particularly neodymium (Nd), for high-performance magnets leads to intensified mining with hazardous wasteWastes and significant environmental harm. Hence, it emphasizes the need for greener alternatives, such as recovering Nd from recycled NdFeB permanent magnets. Molten saltMolten salt chloride enables selective Nd extraction from spent magnets without aqueous wasteWastes and with no carbon emissionEmission. This study undertakes FactSageFactSage thermochemical simulationsSimulation to assess binary and ternary chloride systems NdCl3–LiCl, NdCl3–AlCl3, NdCl3–MgCl2, AlCl3–MgCl2, LiCl–AlCl3, LiCl–MgCl2, and LiCl–AlCl3–MgCl2 for Nd recovery. Phase diagramsPhase diagram and equilibriumEquilibrium calculations at 5, 10, and 15 mol % Nd predicts that LiCl–AlCl3 system yields the lowest eutectic pointEutectic point 485 °C, at LiCl concentration of 56 mol % with 5 mol% Nd due to AlCl3’s strong Lewis acidity. AlCl3's Lewis acidity reduces melting point and enhances Nd solubilitySolubility. The liquidus rises steeply with increasing Nd concentration. MgCl2-rich systems provide the most stable melting behavior over varying Nd content. The LiCl–AlCl3–MgCl2 ternary offers a compromise with moderately low melting points and low sensitivity to Nd concentration. These results identify LiCl–AlCl3 as the optimal binary medium for energy-efficient, low-temperatureTemperature Nd extraction from recycled magnets and provide clear temperatureTemperature and composition for experiment purposes.