This study investigates the removal of aluminum and iron from rare earth element (REE) containing solutions by solvent extraction with saponified naphthenic acid and by hydrolysis-precipitation. The results emphasize both, the preferential application as well as limitations of every method. We find that emulsification occurring during the solvent extraction of aluminum is caused by its slow extraction rate in comparison to the neutralization reaction and by the proximity of the pH value required for aluminum extraction and the pH value at which hydrolysis of aluminum occurs. However, by choosing a long shaking time of at least 4 h, the emulsion recedes. The formation of emulsion can be avoided by strict control of pH value during the extraction. Moreover, the loading capacity of the organic phase with aluminum is limited due to the strong increase in viscosity of the organic phase with increasing aluminum concentration and due to the gel formation. Regarding the extraction of iron, the amount of extracted ions is limited due to the overlap of the pH range required for the extraction with pH range in which sparingly soluble iron oxides/hydroxides are formed. In summary, aluminum and iron can be simultaneously removed from REE-sulfate solution by solvent extraction with saponified naphthenic acid in one extraction stage only from diluted solutions. However, in comparison to the hydrolysis-precipitation method, a higher purity of the solution is achieved. A complete removal of aluminum and iron from concentrated solutions can be achieved in two stages. First, the content of aluminum and iron should be reduced by hydrolysis-precipitation. After that, a high-purity solution can be obtained by subsequent solvent extraction by saponified naphthenic acid.

The rapid development of light-emitting-diode (LED) technology is attributed to its superiority over light sources of earlier generations. Although LED lamps, compared to compact fluorescent lamps, are considered less harmful to the environment, there is still no efficient solution to deal with them at the end of their lifecycle. The first part of the study provides a detailed characterisation of LED lamps, focusing on their most interesting component: the LED module. LED packages attached to the module are highly enriched with Ga, In, Pd, Ag, Au, Sr, Y, Ce, Eu, Gd, and Lu, with the content of each element varying greatly depending on the LED technology. In the second part of this research, two new approaches for liberation and concentration of valuable components from LED modules are presented and compared: a chemical route and a thermal route. The chemical treatment leads to a highly selective separation of LED chips and encapsulation. Enrichment factors up to about 125 are achieved, and a concentrate is obtained containing approximately 14 wt% of the aforementioned valuable components. However, the process requires aromatic solvents, which are viewed as toxic. The thermal treatment results in separation of the aluminium heat sink from all other components of the LED module. Enrichment is approximately ten times lower, but the approach is technically feasible.

Eudialyte, a sodium rich zirconosilicate, is one of the promising sources for REEs (rare earth elements), particularly for HREEs + Y (heavy rare earth elements and yttrium). The key challenge in hydrometallurgical processing is the prevention of silica gel formation and REE separation from resulting multi-element leach solutions. This study deals with the selective extraction of REE from eudialyte concentrate by selective roasting. In this method, metal ions are converted into sulfates, followed by the decomposition of non-REE sulfates in a roasting step and the water leaching of the calcine. The effect of acid addition, roasting temperature, roasting time, pulp density and leaching time is studied. For sufficient conversion of REEs into sulfates, sulfuric acid is added in excess. At a roasting temperature of ≥750 °C sulfates of zirconium, hafnium, niobium, aluminum and iron decompose into sparingly soluble compounds, while REE and manganese sulfates remain stable up to a roasting time of 120 min. The silica present in the calcine is found to be metastable even after roasting. The amount of leached Si⁴⁺ is dependent predominantly on the pH value of the leaching medium. Applying the method, REEs can be efficiently separated from zirconium, hafnium, niobium, aluminum and iron. However, only diluted solutions can be produced. Water leaching of calcine at high solid/liquid ratios causes REE losses resulting from formation of double sulfates and gypsum. The acid excess removed from the reaction mixture in the roasting stage can be simply recovered by treatment of the gas phase.

Solvent extraction is one of the common methods for the recovery of boric acid (or boron) from aqueous solutions. A wide variety of different compounds including monohydric alcohols has been tested, and there is wide recognition that they are rather ineffective compared to other extractants such as diols. Nevertheless, monohydric alcohols find application in industrial processes, demonstrating their efficiency. The intention of this study is to clarify this discrepancy and to provide an overall picture of monohydric alcohols as an extractant for boric acid. Five different monohydric alcohols are the object of this study: n-octanol, 2-ethyl-1-hexanol, 2-butyl-1-octanol, 2-octanol and 3,7-dimethyl-3-octanol. A special focus of this work is the examination of the effect of the structure of the carbon chain and the effect of the composition of the aqueous phase on the extraction efficiency. As well as the extraction efficiency for boric acid, other important properties are examined such as the viscosity of the organic phase, the solubility of alcohols in the aqueous phase and the co-extraction of salts used as a salting-out agent (NaCl, Na2SO4, MgCl2, LiCl, LiNO3). Finally, a numerical algorithm is developed to calculate the relationship between the number of theoretical stages and the phase ratio at equilibrium for selected extraction systems.