Study on Mechanochemical Activation-Enhanced Hydrochloric Acid Leaching of Rare Earth Elements from Roasted NdFeB Waste

NdFeB waste is an important rare earth secondary resource, and the current industrial practice primarily employs a hydrochloric acid preferential dissolution method to recover rare earth elements (REEs). However, approximately 1% of REEs (e.g., cerium oxide, neodymium oxide, praseodymium oxide, and dysprosium oxide) remain in the leaching residue, resulting in low recovery efficiency. This work puts forward mechanochemical leaching (integrating mechanical activation and acid leaching) to replace traditional agitated leaching, which realizes synchronous mechanical activation and acid leaching within a stirred ball mill. A systematic comparison is conducted between these two leaching technologies, and the influences of operational variables on rare earth leaching efficiency are explored. The experimental results reveal that sustained mechanical grinding can pulverize particles down to the submicron level, induce substantial lattice distortion and amorphous transformation, destroy the physical coating of rare earth-bearing phases by iron oxides, and thereby drastically improve the extraction efficiency of REEs. The optimal conditions were determined as follows: stirring speed of 700 r/min, leaching temperature of 85 °C, HCl concentration of 1 mol/L, leaching time of 180 min and solid–liquid ratio of 100 g/L. Furthermore, this study reveals the synchronous evolution mechanism of particle refinement and phase transformation during mechanochemical leaching, providing an alternative and more economical recycling route for NdFeB waste.