Optimization of rare earth magnet recovery processes using oxalic acid in precipitation stripping: Insights from experimental investigation and statistical analysis

Recycling the valuable metals found in spent permanent magnets (REPMs) poses a significant global challenge for the future. This study examines the efficiency of back extraction of rare earth elements (REEs) by oxalic acid solution from di-(2-ethylhexyl) phosphoric acid (D2EHPA) in recycling REPMs. To evaluate the efficiency of this process, several experiments were carried out using designed BOX-Behnken methodology to investigate the effects of various operational and chemical parameters, including stripping solution to loaded organic phase volume ratio (in the range of 1.0–2.0), oxalic acid concentration (ranging from 0.25 to 0.75 M), the stirring rate (ranged between 150 and 350 rpm), and stripping time (ranging from 15 to 45 min) on the REEs recovery and the purity of final production. Analysis of variance was applied to rigorously examine the results statistically. The results showed that more than 85 % of light and 80 % of heavy REEs can be recovered under optimal conditions. Moreover, the final product contained 43.5 % REEs and approximately 0.1 % iron. The stripping experiment using phosphoric acid as the reagent demonstrated ∼57 % light and ∼4 % heavy REEs recovery. Additionally, the recyclability of the organic phase showed its effective reuse for up to four cycles. This study underscores significant progress in the selective recovery of rare earth elements through a relatively straightforward process consuming mild reagents. [Display omitted] •Direct REE oxalate production from loaded D2EHPA using an oxalic acid solution.•A high yield of both light and heavy REEs was achieved with oxalic acid.•The recycled organic phase can be reused multiple times efficiently.•A high-purity REE product with low iron concentration is obtained.