Rare earth element recycling from waste nickel-metal hydride batteries

Highlights: • Leaching kinetics of REEs has rarely been reported. • A new method, including hydrochloric acid leaching and oxalic acid precipitation, was proposed. • REEs recovery rate of 95.16% and pure rare earth oxides of 99% were obtained. • Leaching process was controlled by chemical reaction. • The kinetic equation was determined. - Abstract: With an increase in number of waste nickel-metal hydride batteries, and because of the importance of rare earth elements, the recycling of rare earth elements is becoming increasingly important. In this paper, we investigate the effects of temperature, hydrochloric acid concentration, and leaching time to optimize leaching conditions and determine leach kinetics. The results indicate that an increase in temperature, hydrochloric acid concentration, and leaching time enhance the leaching rate of rare earth elements. A maximum rare earth elements recovery of 95.16% was achieved at optimal leaching conditions of 70 °C, solid/liquid ratio of 1:10, 20% hydrochloric acid concentration, −74 μm particle size, and 100 min leaching time. The experimental data were best fitted by a chemical reaction-controlled model. The activation energy was 43.98 kJ/mol and the reaction order for hydrochloric acid concentration was 0.64. The kinetic equation for the leaching process was found to be: 1−(1−x)^1/3=A/ρr₀[HCl]^0.64exp((−439,800)/(8.314T) )t. After leaching and filtration, by adding saturated oxalic solution to the filtrate, rare earth element oxalates were obtained. After removing impurities by adding ammonia, filtering, washing with dilute hydrochloric acid, and calcining at 810 °C, a final product of 99% pure rare earth oxides was obtained