1:30 PM - *EN01.02.01
Recycling of Rare-Earth Magnets and Lithium Batteries Without Toxic Byproducts
Igor Lubomirsky1,Valery Kaplan1,Ellen Wachtel1,Kyoung-Tae Park2
Weizmann Institute of Science1,Korean Institute of Industrial Technology2
Show Abstract
Sustainable technological development requires recycling of materials, particularly those essential for energy generation and storage, such as the lanthanides and lithium (Li). Recycling of these metals is currently not performed on a large scale, but with growth in demand, one may foresee serious shortages already by the end of the current decade.
High energy density magnets, based on alloys of Nd(+/-Pr +/-Dy)–Fe–B (Nd-alloy), are critical components of a variety of electromechanical and electronic devices. During the last decade, consumption of lanthanide (a.k.a. “rare earth”, RE, element) has risen annually by ≈30%(!!!), primarily due to increased production of hybrid and electric vehicles. Since a standard hybrid/electric automobile requires ≈5-10 kg of RE, while ≈ 40 wt % of the Nd-alloy is lost as scrap during the manufacturing process, large-scale recycling of RE has become an urgent necessity. However, recovery of RE from manufacturing scrap, and especially from end-of-life magnets, poses a difficult technical challenge. The latter requires removing the magnets from the used device, demagnetization, crushing/milling, and applying chemical processes to separate the RE from the Fe component. Demagnetization, by heating in vacuo, and crushing/milling are both costly procedures and the latter may introduce unwanted contamination. Strong acids/bases and/or corrosive melts are currently employed to extract the RE metals. Both routes produce toxic waste, for which the cost of neutralization often exceeds the value of the recovered RE. Instead, we developed an economically and ecologically friendly RE recycling process. Pulverization (decrepitation) into ~ 45mm particles is achieved by introducing atomic hydrogen into the used magnets, without the necessity for prior demagnetization, via room temperature electrolysis in a diluted NaOH solution. Separation of Fe from the RE is achieved by chlorination of the fine powder at ~ 673K, which results in sublimation of chlorides of Fe and B, leaving pure RE chloride. Chlorine gas from non-RE sublimates is recycled, while the RE chlorides may be reduced to metal via moderate temperature eutectic melt electrolysis.
Although Li-batteries initially emerged as a power source for portable devices, incorporation of Li-batteries in vehicles and industrial power banks, led to an exponential growth in the demand for lithium and cobalt. While lithium production is almost exclusively oriented towards batteries, cobalt is also an essential component of high-strength alloys and magnets, with demand for batteries beginning to compete with these traditional applications. Recovery of Li and Co from spent Li-batteries poses technical challenges. In addition to the fact that opening and crushing spent batteries may result in self-ignition, current technologies aim at Co extraction only. Many of these technologies require sequential treatment with acids and bases, producing toxic waste, or involve dumping of crushed batteries into Co-smelting ovens. In both cases, lithium ends up in compounds from which it cannot be readily recovered. We have developed an economical procedure that recovers metallic Co and Ni, and Li in carbonate form. This process is based on treating crushed, spent batteries with natural gas in a rotating kiln at 973K. Following treatment, Co and Ni may be extracted with a magnetic separator and Li2CO3 can be leached out with water, leaving all other components, e.g., compounds of Cu, Mn and Al, for further recycling. Since the proposed process does not use or produce toxic substances, runs at relatively low temperature, yields high recovery for both Co and Li and can be run with simple equipment, it may be considered as suitable for immediate scaling-up and industrial implementation.