Comparison of processing routes for recovery of rare earth elements from discarded fluorescent lamp phosphors

Abstract

This study investigates two phosphor samples with three processing routes to extract rare earth elements (REE). Acid leaching in 2 M HCl, 80 °C, 1 h yielded higher REE extraction in the compact fluorescent lamp (CFL) feed (82% Eu), with varying rare earth (RE) purity (77–97%) compared to fluorescent tubelight (TL) feed (69% Eu, 98–95% purity). Mechanical activation (MA) of 30 and 60 min caused partial dissociation of the LAP (LaPO4:Ce3+Tb3+) phase and yielded 34% Ce, 36% Tb, and 40% La. Transmission electron microscopy results revealed the formation of polycrystalline sites, which improved RE recovery. Alkali baking showed better REE extraction for both phosphors. 86.5% Y, 69% Eu was selectively extracted in feed acid leaching, and 100% La, 60% Tb, 20.6% Eu after alkali baking with 97% purity and CeO2 in the leach residue. The acid baking route was preferred for CFL phosphor with 91% REE (43 % Tb) extraction and 98% purity. TL phosphor was better for Tb extraction. The alkali baking of TL feed and acid baking of CFL feed yields 37.7% and ∼30% rare earth oxides, respectively.