The spent neodymium–iron–boron
(NdFeB) magnet is
a highly valuable secondary resource of rare earth elements (REEs).
Hydrometallurgical processes are widely used in recovering REEs from
spent NdFeB magnets, but they will consume large amounts of organic
chemicals, leading to severe environmental pollution. This work developed
an alternative green route to selectively recover REEs from spent
NdFeB permanent magnets using a purely inorganic zinc salt. The Hammett
acidity measurement showed that concentrated ZnCl2 solutions
could be regarded as a strong Brønsted acid. Concentrated ZnCl2 solutions achieved a high separation factor (>1 ×
105) between neodymium and iron through simple dissolution
of
their corresponding oxide mixture. In the simulated recovery process
of spent NdFeB magnets, the Nd2O3 product was
successfully recovered with a purity close to 100% after selective
leaching by ZnCl2 solution, sulfate double-salt precipitation,
and oxalic acid precipitation. The separation performance of the ZnCl2 solution for Nd2O3 and Fe2O3 remained almost unchanged after four cycles. The energy
consumption and chemical inputs of this process are about 1/10 and half of the traditional hydrometallurgy process
separately. This work provides a promising approach for the green
recovery of secondary REE resources.