Research Projects

Rare Earth Elements (REEs) are critical for sustainable technologies, essential in energy systems, lighting, batteries, and electronics. Rising global demand, price volatility, and supply risks, exacerbated by China’s near-monopoly on REE production, necessitate exploring secondary sources like e-waste. Recycling REEs addresses environmental challenges while reducing dependence on primary resources, which involve low concentrations, radioactive waste, and complex separation processes. Fluorescent lamps (FLs) are a valuable secondary source, containing 25–30% REEs by weight, far higher than natural ores (~1.7%). One ton of phosphor recovered from 0.5–0.75 million FLs equals 19.5 tons of REE ore. Despite this potential, most FLs are discarded in landfills, releasing toxic mercury vapors and wasting resources. In India, approximately 700 million FLs were landfilled in 2018–19, underscoring the urgent need for sustainable recycling methods. This project develops an eco-friendly, economically viable process to recover REEs and other valuable materials from FLs. A custom-designed setup will safely crush FLs while capturing mercury vapors. Crushed glass will be separated for recycling, and phosphor powder will undergo microwave-assisted hydrothermal treatment to enhance REE recovery. Pre-treatments, such as mechanochemical activation, will optimize dissolution efficiency. Extracted REEs (Y, Eu, Tb, La) will be converted into high-purity rare earth oxides (REOs) using advanced solvent extraction techniques, achieving over 95% purity. Selective separation will prioritize REEs by economic value, such as terbium and europium. Thermal and hydrometallurgical treatments will ensure low energy consumption, cost efficiency, and reusable phosphor materials. Comprehensive studies on reaction kinetics, thermodynamics, and energy consumption will optimize processes. Techno-economic and environmental impact assessments will ensure scalability and sustainability. By mitigating mercury toxicity, reducing import dependence, and supporting circular economy principles, this project aligns with India’s Semiconductor Mission, advancing urban mining and fostering socio-economic development.