Selective electrodeposition of dysprosium in LiCl-KCl-GdCl3-DyCl3 melts at magnesium electrodes: Application to separation of nuclear wastes

Advances in bio/chemical approaches for sustainable recycling and recovery of rare earth elements from secondary resources

Rare Earth Elements (REEs) are indispensable in the growing smart technologies, such as smart phones and electronic devices, renewable energy, new generation of hybrid cars, etc. These elements are naturally occurring in specific geological deposits (bastnäsite, monazite, and xenotime), primarily concentrated in the regions of China, Australia, and the USA. The extraction and processing of REEs and the mismanagement of secondary REE resources, such as industrial waste, end-of-life materials, and mining by-products, raise major environmental and health concerns. Recycling represents a convincing solution, avoiding the necessity to separate low-value or coexisting radioactive elements when REEs are recovered from raw ore. Despite these advantages, only 1 % of REEs are usually recycled. This review overreached strategies for recycling REEs from secondary resources, emphasizing their pivotal role. The predominant approach for recycling REEs involves hydrometallurgical processing by leaching REEs from their origins using acidic solutions and then separating them from dissolved impurities using techniques like liquid-liquid extraction, membrane separation, chromatography, adsorption, flotation, and electrochemical methods. However, these methods have notable disadvantages, particularly their over requirements for water, reagents, and energy. Biohydrometallurgy introduces an innovative alternative using microorganisms and their metabolites to extract REEs through bioleaching. Other investigations are carried out to recover REEs through biological strategies, including biosorption, affinity chromatography with biological ligands, bioflotation employing biological surfactants, and bioelectrochemical methods. However, biohydrometallurgical processes can also be relatively slow and less suitable for large-scale applications, often lacking specificity for targeted REEs recovery. Overcoming these challenges necessitates ongoing research and development efforts to advance recycling technologies.

Electrochemical approaches for selective recovery of critical elements in hydrometallurgical processes of complex feedstocks

Critical minerals are essential for the ever-increasing urban and industrial activities in modern society. The shift to cost-efficient and ecofriendly urban mining can be an avenue to replace the traditional linear flow of virgin-mined materials. Electrochemical separation technologies provide a sustainable approach to metal recovery, through possible integration with renewable energy, the minimization of external chemical input, as well as reducing secondary pollution. In this review, recent advances in electrochemically mediated technologies for metal recovery are discussed, with a focus on rare earth elements and other key critical materials for the modern circular economy. Given the extreme heterogeneity of hydrometallurgically-derived media of complex feedstocks, we focus on the nature of molecular selectivity in various electrochemically assisted recovery techniques. Finally, we provide a perspective on the challenges and opportunities for process intensification in critical materials recycling, especially through combining electrochemical and hydrometallurgical separation steps.

Electrodeposition of neodymium and dysprosium from organic electrolytes

A new class of organic electrolytes has been developed for the electrodeposition of rare-earth metals at room temperature. These electrolytes consist of a rare-earth bis(trifluoromethylsulfonyl)imide or chloride salt and a borohydride salt, dissolved in the ether solvents 1,2-dimethoxyethane or 2-methyltetrahydrofuran. In these electrolytes, a soluble lanthanide(iii) borohydride complex [Ln(BH4)4]- is formed, which allows for the electrodeposition of neodymium- or dysprosium-containing layers. The electrochemistry of these electrolytes was characterized by cyclic voltammetry. The deposits were characterized by scanning electron microscopy (SEM), energy-dispersive X-ray fluorescence (EDX) and X-ray photoelectron spectroscopy (XPS), and the results suggest the presence of metallic neodymium and dysprosium.

Electrochemical Removal of Rare Earth Element in LiCl-KCl Molten Salt

This study was carried out to examine the removal of rare earth (RE) elements by electrodeposition for the purification and reuse of LiCl-KCl salt after electrorefining and electrowinning. The electrochemical behavior of RE elements (Dy and Gd) in LiCl-KCl-DyCl3-GdCl3 at 500°C was investigated using the cyclic voltammetry (CV) technique using Mo and Mg electrodes. It was observed that the reduction potential of the RE elements shifted at the Mg electrode owing to the alloy formation with Mg (RE-Mg alloy). Subsequently, a series of potentiostatic electrolysis tests were conducted to remove the RE elements in the salt and check the formation of deposits at the Mg and Mo electrodes. The scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM/EDS) technique was used to confirm that the reduced RE metals were deposited on the surface of the Mg electrode. However, no significant deposit on the Mo electrode was observed, and a mud-like deposit was found on the bottom of the electrochemical cell. The salt analysis performed by employing the inductively coupled plasma-optical emission spectrometry (ICP-OES) indicated that the removal efficiency of Dy3+ and Gd3+ through electrodeposition was 83.5∼95.2 and 91.6∼95.2%, respectively.

Selective morphological analysis of cerium metal in electrodeposit recovered from molten LiCl-KCl eutectic by radiography and computed tomography

This paper presents, for the first time, a study to analyze the surface morphology of metal extracted from a high temperature molten salt medium in the electrodeposit using x-ray radiography and computed tomography. Widely used methods such as scanning electron microscopy and inductively coupled plasma-optical emission spectrometry/mass spectrometry are destructive and the related processes are often subject to the air condition. The x-ray imaging can provide rich information of the target sample in a non-destructive way without invoking hydrolysis or oxidation of a hygroscopic sample. In this study, the x-ray imaging conditions were optimized as following: tube voltage at 100 kVp and the current exposure time product at 8.8 mAs in our in-house x-ray imaging system. LiCl-KCl and cerium metals used in this work produced substantially distinguishable contrasts in the radiography due to their distinctive attenuation characteristics, and this difference was well quantified in the histograms of brightness. Electrodeposits obtained by chronoamperometry and chronopotentiometry demonstrated a completely different behavior of electrodeposition even at the same applied charge. In particular, computed tomography and volumetric analysis clearly showed the structural and morphological dissimilarity. The structure of cerium metal in the electrodeposit was successfully separated from the chloride salt structure in the CT image by an image segmentation process.

Electrolytic extraction of dysprosium and thermodynamic evaluation of Cu-Dy intermetallic compound in eutectic LiCl-KCl

The electrochemical reduction of dysprosium(iii) was studied on W and Cu electrodes in eutectic LiCl–KCl by transient electrochemical methods. Cyclic voltammogram and current reversal chronopotentiogram results demonstrated that dysprosium(iii) was directly reduced to dysprosium (0) on the W electrode through a single-step process with the transfer of three electrons. Electrochemical measurements on the Cu electrode showed that different Cu–Dy intermetallics are formed. Moreover, the thermodynamic properties of Cu–Dy intermetallic compounds were estimated by open circuit chronopotentiometry in a temperature range of 773–863 K. Using the linear polarization method, the exchange current density (j₀) of dysprosium in eutectic LiCl–KCl on the Cu electrode was estimated, and the temperature dependence of j₀ was studied to estimate the activation energies associated with Dy(iii)/Cu₅Dy and Dy(iii)/Cu_9/2Dy couples. In addition, potentiostatic electrolysis was conducted to extract dysprosium on the Cu electrode, and five Cu–Dy intermetallic compounds, CuDy, Cu₂Dy, Cu_9/2Dy, Cu₅Dy and Cu_0.99Dy_0.01 were identified by X-ray diffraction, scanning electron microscopy and energy dispersive spectrometry. Meanwhile, the change of dysprosium(iii) concentration was monitored using inductively coupled plasma-atomic emission spectrometry, and the maximum extraction efficiency of dysprosium was found to reach 99.2%.

The electrochemical reduction of dysprosium(iii) was studied on W and Cu electrodes in eutectic LiCl–KCl by transient electrochemical methods.