Development of an Ecological Process for Nd-Fe-B Permanent Magnet Recycling : Hydrothermal Way, Mechanical Milling ; Développement d'un procédé écologique pour le recyclage des aimants permanents Nd-Fe-B : voie hydrothermale, broyage.

Rare earth supplying is a very current topic, linked to the rare earth crisis of 2010. « Urban mining » is a promising path for recycling rare earths included in waste daily generated by industralized countries. In this work, we focus on recycling Nd-Fe-B permanent magnets, because they are a very interesting deposit for Neodymium, but also for Dysprosium and Praseodymium. More precisely, permanent magnets included in hard disks drives have been considered. The objective of this work is to set up environmentally friendly and low cost recycling processes for rare earths. First, we investigated hydrothermal treatment of Nd-Fe-B permanent magnets, We developed a new and environmentally friendly approach for recycling Ni−Cu coated Nd-Fe−B permanent magnets included in computer hard disk drives. In a closed reactor, the coated magnets are heated at 250 °C in water mixed with sodium chloride for up to 18 h. First, the hydrothermal treatment induces the removal of the metallic coating that can be recovered by sieving. Then, the Nd-rich phase reacts with water, leading to the formation of Nd(OH)3. Atomic hydrogen is absorbed by the Nd2Fe14B phase, leading to the formation of Nd2Fe14BHx. The volume expansion of the intergranular phase, in relation to the formation of Nd(OH)3, together with the lattice expansion of the Nd2Fe14BHx phase causes the disintegration of the magnets. Finally, Nd2Fe14BHx is oxidized by water into Fe3O4 and Nd(OH)3. The Nd(OH)3 crystals can be isolated from the Fe3O4 crystals by magnetic separation. This process is thus an easy way to extract rare earths from permanent magnets found in WEEE. It uses green chemistry design principles and can be applied to large amounts of magnetic wastes. Mechanical milling of Nd-Fe-B permanent magnets has also been investigated, and, in the study presented here, the milling effect on the magnetic properties of the Nd2Fe14B intermetallic was investigated using SQUID measurements, Mössbauer spectrometry and atom probe tomography (APT). Mechanical milling of the ...