The thermodynamics and kinetics of ethanol antisolvent crystallization of rare earths from sulfate solutions has been explored, with a view towards separating the rare earths as part of a NdFeB magnet recycling process. The solubility of single and binary metal (Nd, Pr, Fe) phases in aqueous ethanol solutions has been determined. The impact of Fe and Pr on the crystallization of Nd is evaluated, the oxidation kinetics of Fe(II) to Fe(III) quantified, and the influence of Fe oxidation state on the thermodynamics and kinetics of crystallization investigated. Oxidation to Fe(III) is slow, with a half life of approx. 600 h. For pure Nd, the solubility of the obtained, stable sulphate octahydrate decreases exponentially with increased molar organic:aqueous (O/A) ratio, and is well described by the OLI model until O/A=0.2. Pr crystallizes as an isostructural octahydrate with similar solubility. Fe(II) precipitates as a mixed solid phase, with a solubility approximately 40 times higher than the rare earths at O/A=0.2. Fe(III) solutions exhibit liquid–liquid phase separation without precipitation at all evaluated concentrations. Nd and Pr coprecipitate together in proportion to their relative concentrations, with Pr precipitating at concentrations well below its pure component solubility. Fe(II) does not precipitate with Nd at O/A≤0.2 even at high concentration, with significant precipitation as separate particles at higher O/A for all concentrations. The crystallization kinetics and the morphology of the Nd phase is affected by the Fe oxidation state. The work highlights the potential of antisolvent crystallization for selective and efficient separation of REE from Fe.

The flexible and reversible preparation of columns for use in high-performance solid phase extraction chromatography by physisorption of organophosphorus acid extractants has been investigated in detail. Two extractants have been evaluated, bis (2-ethyl-1-hexyl) phosphoric acid (HDEHP) and 2-ethyl-1-hexyl (2-ethyl-1-hexyl) phosphonic acid (HEHEHP), but the developed procedure should be broadly applicable to other extractants. The liquid-liquid solubility of the extractants in feed solvents consisting of aqueous ethanol solutions of varying composition has been determined. The total amount of adsorbed extractant has been quantified by complete desorption and elution with ethanol followed by acid-base titrimetry. Column impregnation with feed solutions of varying concentration in the undersaturated region has been systematically evaluated, and the influence of a subsequent water wash step has been explored. It is shown that to achieve a robust and reproducible physisorption, the adsorbed amount of extractant should be determined after the wash step, and care must be taken when using indirect methods of measurement. Equilibrium Langmuir-type adsorption isotherms as a function of the extractant concentration in the feed solution have been determined. Adsorption of HEHEHP is higher than HDEHP for equal feed compositions, but the solubility of HEHEHP is lower, resulting in approximately identical maximum coverage levels. The ability of the resulting columns to separate rare earth elements have been verified for a mixture of eight metals using a combined isocratic and gradient elution of nitric acid.

Developing efficient and viable processes for separation of critical metals is essential to meet the increasing demand. Rare earth elements (REEs) are identified by the EU as critical resources, and moreover, they are difficult to separate due to their similar properties. Extraction chromatography is a powerful method suitable for difficult, high-purity separations, which could form part of a separation process for recovery of REEs from various sources. In the present work, separation of REEs from synthetic apatite leach solutions is investigated using physically immobilized extractants. By means of reverse-phase columns, reversibly functionalized by acidic organophosphorus compounds, the metals are separated by elution with nitric acid solution.