NdFeB stands as the foremost utilized material in permanent magnet applications, generating substantial quantities of NdFeB magnet waste annually. These wastes contain 20−30 wt. % rare earth elements (REEs) and are valuable secondary resources. In this paper, Bi was used as extractant to recover REEs in NdFeB waste by pyrometallurgy, and excess Bi was separated by supergravity technology for recycling. The migration and diffusion behaviors of REEs during the extraction process were investigated, with the diffusion coefficient of REEs in Bi obtained. The influence of Bi-to-waste mass ratio on rare earth extraction efficiency in smelting process, alongside the effect of temperature and gravity coefficient on the Bi recovery rate in supergravity centrifugation process were delineated. Findings revealed that the diffusion of Nd in Bi and NdFeB conformed to Fick's second law. Notably, with a Bi-to-waste mass ratio surpassing 1:1, spontaneous separation occurred between the Bi and Fe phases, facilitating the migration of almost all REEs from NdFeB waste into the Bi phase. Under the optimal conditions (Bi/NdFeB mass ratio of 4:3, separation temperature of 500°C and a gravity coefficient of 1000), the recovery rate of REEs during the smelting stage reached 99.6%, while the Bi recovery rate during the supergravity stage was 74.7%. Additionally, the overall REE recovery rate and Bi recovery rate during the entire process reached 99.3% and 70.3%, respectively. The successful development of this process has opened up a new way for recycling REEs from NdFeB waste.
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