Only about 1 percent of rare earth elements in old products are recycled. Why don’t we recycle more of them?
Rare earths are often blended with other metals in touch screens and similar products, making removal difficult. In some ways, recycling rare earths from tossed-out items resembles the challenge of extracting them from ore and separating them from each other. Traditional rare earth recycling methods also require hazardous chemicals such as hydrochloric acid and a lot of heat, and thus a lot of energy.
In experiments, the bacterial acids can recover only about a quarter to half of the rare earths from spent catalysts and phosphors. Hydrochloric acid can do much better — in some cases extracting as much as 99 percent. But bio-based leachingIn a hypothetical plant recycling 19,000 metric tons of used catalyst a year, the team estimated annual revenues to be roughly $1.75 million. But feeding the bacteria that produce the acid on-site is a big expense.
In a best-case scenario, using this method to recycle 100 tons of leftover magnet material might produce 32 tons of rare earth oxides and net more than $1 million in profits, an economic analysis of the method suggests. Meanwhile, the technology seems promising enough that TdVib, an Iowa company that designs and manufactures magnetic materials and products, has licensed it and built a pilot plant. The initial aim is to produce two tons of rare earth oxides per month, says Daniel Bina, TdVib’s president and CEO. The plant will recycle rare earths from old hard disk drives from data centers.
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