Solvent-driven fractional crystallization for atom-efficient separation of metal salts from permanent magnet leachates

Caleb Stetson, Denis Prodius, Hyeonseok Lee, Christopher Orme, Byron White, Harry Rollins, Daniel Ginosar, Ikenna C. Nlebedim and Aaron D. Wilson ()
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Caleb Stetson: Critical Materials Institute, Idaho National Laboratory, 1955 N Fremont Ave
Denis Prodius: Critical Materials Institute, Ames Laboratory, US Department of Energy
Hyeonseok Lee: Critical Materials Institute, Idaho National Laboratory, 1955 N Fremont Ave
Christopher Orme: Critical Materials Institute, Idaho National Laboratory, 1955 N Fremont Ave
Byron White: Critical Materials Institute, Idaho National Laboratory, 1955 N Fremont Ave
Harry Rollins: Critical Materials Institute, Idaho National Laboratory, 1955 N Fremont Ave
Daniel Ginosar: Critical Materials Institute, Idaho National Laboratory, 1955 N Fremont Ave
Ikenna C. Nlebedim: Critical Materials Institute, Ames Laboratory, US Department of Energy
Aaron D. Wilson: Critical Materials Institute, Idaho National Laboratory, 1955 N Fremont Ave

Nature Communications, 2022, vol. 13, issue 1, 1-9

Abstract: Abstract This work reports a dimethyl ether-driven fractional crystallization process for separating rare earth elements and transition metals. The process has been successfully applied in the treatment of rare earth element-bearing permanent magnet leachates as an atom-efficient, reagent-free separation method. Using ~5 bar pressure, the solvent was dissolved into the aqueous system to displace the contained metal salts as solid precipitates. Treatments at distinct temperatures ranging from 20–31 °C enable crystallization of either lanthanide-rich or transition metal-rich products, with single-stage solute recovery of up to 95.9% and a separation factor as high as 704. Separation factors increase with solution purity, suggesting feasibility for eco-friendly solution treatments in series and parallel to purify aqueous material streams. Staged treatments are demonstrated as capable of further improving the separation factor and purity of crystallized products. Upon completion of a crystallization, the solvent can be recovered with high efficiency at ambient pressure. This separation process involves low energy and reagent requirements and does not contribute to waste generation.

Date: 2022
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DOI: 10.1038/s41467-022-31499-7

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