There
is a global need for efficient and environmentally sustainable
processes to close the life cycle loop of waste electrical and electronic
equipment (WEEE) through recycling. Conventional WEEE recycling processes
are based upon pyrometallurgy or hydrometallurgy. The former is energy-intensive
and generates greenhouse gas (GHG) emissions, while the latter relies
on large volumes of acids and organic solvents, thus generating hazardous
wastes. Here, a novel “aeriometallurgical” process was
developed to recycle critical rare earth elements, namely, neodymium
(Nd), praseodymium (Pr), and dysprosium (Dy), from postconsumer NdFeB
magnets utilized in wind turbines. The new process utilizes supercritical
CO2 as the solvent, which is safe, inert, and abundant,
along with the tributyl-phosphate–nitric acid (TBP–HNO3) chelating agent and 2 wt % methanol as a cosolvent. Nd (94%),
Pr (91%), and Dy (98%) extraction was achieved with only 62% iron
(Fe) coextraction and minimal waste generation. Fundamental investigations
into the extraction mechanism demonstrated that metal ion charge has
an important impact on the extraction efficiency. Fundamental investigations
indicate that extraction proceeds by corrosion of the magnet particle’s
surface layer. This work demonstrates that supercritical fluid extraction
would find widespread applicability as a cleaner, a more sustainable
option to recycle value metals from end-of-life products to enable
the circular economy.