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Complete recycling of Nd 2 Fe 14 B sludge by chemical methods has gained significance in recent years, however, it is not easy to recycle highly contaminant sludge and obtain product with good magnetic properties. Herein we report a simple four-step process to recycle the Nd 2 Fe 14 B sludge containing ~ 10% of contaminants. Sludge was leached in H 2 SO 4  and selectively co-precipitated in two steps. In the first co-precipitation, Al 3+  and Cu 2+  were removed at pH 6. Thereafter, in the second co-precipitation Fe 2+  and RE 3+  sulfates were converted to the Fe and RE hydroxides. By annealing at 800 °C RE and Fe hydroxides precipitates were converted to the oxides and residual carbon was oxidized to CO 2 . After the addition of boric acid, Fe and RE oxides were reduced and diffused to the (Nd-RE) 2 Fe 14 B by calciothermic reduction diffusion. Removal of CaO by washing with D.I. water in glove box reduced the oxygen content (~ 0.7%), improved crystallinity and enhanced the magnetic properties significantly. Coercivity increased more than three times (from 242.71 to 800.55 kA/m) and M r  value was also enhanced up to more than 20% (from 0.481 to 0.605 T). In this green process Na 2 SO 4  and Ca(OH) 2  were produced as by-product those are non-hazardous and were removed conveniently.

Four-step eco-friendly energy efficient recycling of contaminated Nd2Fe14B sludge and coercivity enhancement by reducing oxygen content