WO2004101202A1 - 希土類-遷移金属系スクラップのリサイクル方法、電波吸収用磁性体粉末及びそれを用いた電波吸収体 - Google Patents
希土類-遷移金属系スクラップのリサイクル方法、電波吸収用磁性体粉末及びそれを用いた電波吸収体 Download PDFInfo
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- WO2004101202A1 WO2004101202A1 PCT/JP2004/007029 JP2004007029W WO2004101202A1 WO 2004101202 A1 WO2004101202 A1 WO 2004101202A1 JP 2004007029 W JP2004007029 W JP 2004007029W WO 2004101202 A1 WO2004101202 A1 WO 2004101202A1
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- rare earth
- transition metal
- scrap
- fine particles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/33—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials mixtures of metallic and non-metallic particles; metallic particles having oxide skin
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B59/00—Obtaining rare earth metals
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
- C22B7/001—Dry processes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/54—Reclaiming serviceable parts of waste accumulators
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/008—Disposal or recycling of fuel cells
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/09—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials mixtures of metallic and non-metallic particles; metallic particles having oxide skin
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/84—Recycling of batteries or fuel cells
Definitions
- the present invention includes both rare earth-transition metal scraps mainly generated from metal scrap and non-metallic compositions such as slag generated during the production or disposal of rare earth magnets or hydrogen storage alloys.
- rare earth permanent magnets High-performance rare-earth magnets have long been used in information and communication equipment, control equipment, consumer light electrical equipment using small motors, and medical diagnostic equipment. There is an increasing trend.
- hydrogen-absorbing alloys are attracting attention as a field that consumes a large amount of rare earth metal in parc.
- inexpensive misch metal instead of La-separated rare earth Since it became possible to use nickel-hydrogen batteries, they are still actively used, mainly as anode materials for nickel-hydrogen secondary batteries.
- magnet scraps such as defective sintering and cutting waste generated during the manufacturing process are a large percentage of the amount of magnetic alloy used as a raw material. Specifically, in Japan alone in 2001, about 9,000 tonnes of magnetic alloys are manufactured annually, but this is equivalent to about 7,000 tonnes of magnet products per year. When it is machined, a part of about 2,000 tons (approximately less than 30% of the total magnet production weight) turns into defective products with no commercial value, such as cracks and chips, and scraps such as grinding waste. ing. It is also expected that the amount of magnet scrap discarded as a medium product will increase at an accelerated rate in the future.
- a Ni plating film may be formed as a protection treatment.
- Ni is a factor that reduces the remanent magnetization in the Nd_Fe_B-based sintered magnet, so the sintered magnet scrap having the Ni plating film is reused as a raw material for the sintered magnet. In such a case, it is considered necessary to remove and remove it.
- a method of absorbing and releasing hydrogen into a sintered magnet to form a powder frame, separating only the Ni plating film, and using the remaining powder as a raw material alloy Japanese Unexamined Patent Publication No. Hei 5-33073
- a method has been proposed in which a Ni film is separated by mechanical means such as shot beaning and the remaining powder is used as a raw material alloy (Japanese Patent Application Laid-Open No. 13-44025).
- Rare earth sintered magnets generate a lot of scrap in process (2), and in order to utilize recycled resources in the market in the future, a method with good production efficiency and low renewable energy is required.
- the above method (1) requires a large amount of acid to dissolve the scrap, and therefore has environmental issues such as a problem of treating the used acid solution and iron component residue.
- the method (2) also requires a large amount of heat energy to produce potassium metal and reduce scrap by the method, and also requires complicated washing and removal of calcium oxide, a by-product of the reduction treatment, from the reduced powder. Involves many steps.
- carbon remains as impurities in the reduced rare-earth metal, which is not suitable for the production of high-performance magnets, whose demand has been growing remarkably recently.
- the Ni film peeling method (3) has problems that it is difficult to completely separate the Ni film and that it takes time to recycle the raw material alloy.
- the method of re-milling a sintered magnet, press-molding it, and sintering it again to form a magnet is used industrially because the magnetic properties are significantly reduced due to oxidation of the powder and deterioration of the particle size distribution. Not been.
- the method of pulverizing a sintered magnet to use as a raw material for a bonded magnet requires a lot of man-hours for sieving the powder, and generates a large amount of fine powder that cannot be used for the bonded magnet, resulting in a remarkably low recycling rate. As such, it is rarely used.
- the present invention provides a method for inexpensively and effectively recycling rare earth-transition metal scrap generated during the production or disposal of a rare earth magnet or a hydrogen storage alloy, beyond the recycling of the same material, and a method for recycling the same. It is an object of the present invention to provide a magnetic material powder for radio wave absorption that can be manufactured at low cost using a resultant material and that can obtain a high-performance radio wave absorber, and a radio wave absorber using the same. Disclosure of the invention
- the method for recycling the scrap according to the present invention comprises:
- Method for recycling rare earth-transition metal scrap (hereinafter simply referred to as scrap)
- Heat treatment of the scrap in an oxygen-containing atmosphere results in an average particle size of 500 nm based on the oxidation reaction, which has a higher transition metal content than the rare earth-transition metal intermetallic compound that forms the main component of the scrap.
- a disproportionation reaction treatment is performed in which the following transition metal-based magnetic fine particles and surplus rare earth metal are mainly separated and rare earth oxide particles having an average particle diameter of 500 nm or less are generated by decomposition.
- the scrap is regenerated as a radio-wave-absorbing magnetic powder composed of a composite of transition metal-based fine metal particles and a rare earth oxide.
- the magnetic material powder for radio wave absorption of the present invention is produced by the recycling method of the present invention, and is composed of a composite mainly composed of transition metal-based magnetic fine particles and rare earth oxide fine particles.
- the radio wave absorber of the present invention is obtained by mixing the above-mentioned magnetic powder for radio wave absorption of the present invention with a binder and molding the mixture.
- main component also defined as “mainly” or “mainly” refers to a component having the highest content in mass%.
- alloy is included in the concept of “metal”
- intermetallic compound is treated as included in the concept of “alloy”.
- transition metals mainly include Fe, Co, and Ni, and these magnetic transition metals are mainly responsible for radio wave absorption performance.
- it can be suitably used in the present invention.
- defective products generated during the production of rare earth magnets and hydrogen storage alloys include solid scraps such as cracks and missing products.
- unnecessary residues that do not constitute a product include slag generated when the raw material alloy is melted and solid or powdered scrap such as sludge generated by cutting, grinding and the like.
- solid scrap and powdered scrap are also found in waste products collected from used products equipped with rare earth magnets or hydrogen storage alloys.
- an extremely fine transition metal-based metal having a high transition metal element content and an average particle diameter of 500 nm or less.
- the fine particles form rare earth oxides
- a mixed powder mixed at a low level can be obtained.
- the transition metal-based metal fine particles are composed of a transition metal-based metal or an alloy phase.
- a simple metal such as a-Fe, an alloy such as Fe-Ni or Fe-Co-based, It contains compounds such as e 2 B and Fe 3 B, which exhibit soft or hard magnetic properties and can be used as excellent radio wave absorbing materials.
- rare earth magnets or scraps of hydrogen-absorbing alloy which had not been recycled so far in the past, can be converted to high value-added radio wave absorbing materials at a high recycling ratio and at low cost.
- Electromagnetic waves are now being used in a wide variety of fields, as shown in Figure 1, and are an integral part of our lives.
- satellite broadcasting wireless LAN systems, mobile phones, simplified mobile phones (PHS), and computers with high-frequency CPU clocks, and even millimeter-wave bands that can be used outdoors in the field of wireless LAN.
- ETC Electronic Toll Collection System
- rear-end collision prevention radar etc.
- the use of GHz band electromagnetic waves is becoming more and more popular.
- Electromagnetic waves propagate through space as signals for transmitting information.Even if they are information signals for a given device, they may cause jamming waves for other devices. As devices become smaller and lighter, electronic devices with highly integrated semiconductor components are susceptible to malfunctions because they are sensitive to external noise. In addition to electromagnetic waves intentionally radiated from the electromagnetic wave source, there are also electromagnetic waves leaking from equipment, communications, wiring, etc., and electromagnetic waves transiently generated when the power switch is turned on and off. However, modern electronic devices that are mainstream are more susceptible to obstacles than conventional analog devices It causes movement.
- the electromagnetic wave absorber requires that the electromagnetic energy is taken into the object, and that the taken-in electromagnetic energy is efficiently converted to heat energy and then eliminated (heat radiation).
- the principles of electromagnetic wave absorbers are classified into conductive loss, dielectric loss, and magnetic loss. Materials corresponding to these include conductors (metals, etc.), dielectrics (metal oxides, etc.), and magnetic materials (ferrites, which are metal oxides, etc.), and their use is expected to expand in the future.
- a magnetic material that is capable of forming a thin absorber with good absorption efficiency is promising.
- the feature of the recycling method of the present invention is that the scrap of the rare earth magnet or the hydrogen storage alloy is not recycled to the same kind of material (that is, the rare earth magnet or the hydrogen storage alloy), but goes beyond the framework of the material.
- the point is to convert into a radio wave absorber by reusing the high chemical reaction activity of metal components with oxygen and the like.
- Rare-earth magnets or hydrogen-absorbing alloys contain a large amount of rare-earth components in a metallic state, and their oxidation and deterioration have progressed (for example, those with an oxygen content exceeding 300 ppm). There was a limit to recycling in large quantities within the framework of similar materials.
- the present inventors changed their ideas there, and oxidized the rare earth-transition metal alloy forming the rare earth magnet or the hydrogen storage alloy at a certain temperature or higher (disproportionation reaction treatment).
- disproportionation reaction treatment oxidized the rare earth-transition metal alloy forming the rare earth magnet or the hydrogen storage alloy at a certain temperature or higher.
- the transition metal-based metal or alloy phase generated during the disproportionation reaction of ⁇ is an elementary metal or alloy such as ⁇ -Fe, Fe_Ni, Fe_Co, etc. with an average particle size of 500 nm or less.
- Rare earth oxides are substances that are directly linked to performance degradation as degradation reaction products from the standpoint of rare earth magnets or hydrogen storage alloys. The emphasis is on how to keep the content of degradation reaction products in the product low. It can be said that.
- the concept of "regeneration into the same kind of material” is abandoned, and a considerable portion of the rare earth component contained in the scrap is rather actively converted into a compound of the same system as the degradation reaction product, which is completely different. It is unique in that it is recycled as a radio wave absorber, which is a material.
- the degradation reaction products such as oxides originally contained in the scrap are assimilated into the aggressively formed oxides.
- transition metal-based or transition metal compound-based magnetic fine particles As a rare-earth acid compound phase that improves radio wave absorption properties, due to its excellent insulation properties, transition metal-based or transition metal compound-based magnetic fine particles, which are good conductors, are used as functional material phases that electrically isolate each other. Can be used. As a result, the present invention makes it possible to recycle scraps of rare-earth magnets or hydrogen-absorbing alloys, which were considered difficult to reuse, as a material for radio wave absorbers without any problems. large.
- radio wave absorbing materials obtained by recycling such rare earth magnets or hydrogen storage alloys have unexpectedly good radio wave absorption characteristics compared to conventional radio wave absorbing materials.
- radio wave absorbers used in the GHz band especially l GHz to 20 GHz
- ferrite hard magnetic materials or metallic magnetic materials having shape magnetic anisotropy. I was Here, the former is an oxide because it is originally an oxide There was no significant loss, but there was a problem that magnetic absorption was low and sufficient absorption was not obtained (S.
- the magnetic material powder for radio wave absorption obtained by the recycling method of the present invention has a structure in which transition metal magnetic fine particles are separated by, for example, rare earth oxide fine particles having high resistivity.
- the raw materials used are originally used for the production and disposal of rare earth magnets and hydrogen storage alloys. It is needless to say that the raw material cost can be significantly reduced because it is a rare earth-transition metal alloy and intermetallic compound scrap generated by the process.
- the entire material may be made of a rare earth-transition metal alloy scrap, or a part of the raw material may be replaced with a material other than the rare earth-transition metal alloy scrap for composition adjustment or the like.
- the transition metal-based magnetic fine particles are partially recombined with one or more of boron, carbon, silicon, and nitrogen contained in scrap at the time of the disproportionation reaction, or Before or after the treatment (which may be before or after) A separate atmosphere heat treatment is performed, and one or more of hydrogen, boron, carbon, silicon, and nitrogen contained in the atmosphere are performed.
- This compound may be one that re-decomposes during the disproportionation reaction treatment or the heat treatment in the atmosphere, or may remain as a compound after the treatment.
- the decomposition reaction allows the transition metal-based magnetic fine particles to be further miniaturized, contributing to further improvement of the radio wave absorption characteristics.
- a new radio wave absorption peak is generated in the frequency range peculiar to the compound to be formed, so that the bandwidth in which radio wave absorption becomes remarkable can be extended. There is.
- one containing one or more of boron, carbon, silicon, and nitrogen in addition to oxygen as an impurity component can be used, and this can be used as the compound-forming component.
- Atmospheric heat treatment which is performed separately from the disproportionation reaction treatment, may be performed before or after the disproportionation reaction treatment in an oxygen-containing atmosphere by one or more of hydrogen, boron, carbon, silicon, and nitrogen.
- hydrogen, boron, carbon, silicon, and nitrogen contained in the gas atmosphere are used as the compound-forming component.
- Hydrogen, boron, carbon, silicon and nitrogen can be contained as a single gas component such as hydrogen and nitrogen, as well as boron containing hydrogen (for example, boron hydride), hydrocarbons, carbon dioxide, etc.
- the volume concentration of the gas serving as a component source of hydrogen, boron, carbon, silicon, or nitrogen in the entire atmosphere gas is as described below. volume. / 0 or more and 100% by volume or less, and the processing temperature is preferably room temperature or more and 100 ° C. or less.
- the magnetic powder for electromagnetic wave absorption is a transition generated as a result of the above-described compounding with boron, carbon, silicon, and nitrogen during the disproportionation reaction treatment or the atmosphere heat treatment separately performed.
- the radio wave absorption characteristics can be further improved, and the frequency band in which good radio wave absorption characteristics can be obtained can be extended.
- the transition metal compound-based magnetic fine particles are preferably used as containing one or more of boron, carbon, silicon, and nitrogen as a compound-forming component. Particularly, compounds with boron or silicon have good chemical stability.
- the transition metal compound-based magnetic fine particles can be redissolved during the disproportionation reaction treatment or the heat treatment in the atmosphere, and the fineness of the magnetic fine particles obtained after the decomposition can be further promoted.
- Such transition metal compound-based magnetic fine particles that are premised on re-decomposition are those that easily re-decompose, specifically those that contain hydrogen as a compound-forming component (that is, those mainly composed of hydrides). It is better to use.
- boron, silicon, nitrogen, oxygen, and trace metals which are the original constituent components of scrap or unavoidable impurities, are added.
- a compound-forming component gas consisting of one or more of boron, carbon, silicon and nitrogen together with the component source gas, the same boride of transition metal-based magnetic fine particles generated as a disproportionation reaction treatment , Carbides, silicides and nitrides can be simultaneously promoted.
- the disproportionation decomposition between the scrap components progresses more efficiently.
- Performing in a gas atmosphere containing one or more of oxygen, boron, carbon, silicon, and nitrogen makes it possible to perform the disproportionation reaction treatment and thereby use the transition metal-based magnetic fine particles or transition metal compound-based material.
- the generation of magnetic fine particles can be promoted, and it becomes easy to obtain higher performance magnetic material powder for radio wave absorption.
- the volume concentration of the gas components serving as hydrogen, boron, carbon, silicon, and nitrogen component sources in the entire atmosphere gas is 1 volume. Desirably, it is not less than / 0 and not more than 100% by volume.
- the volume concentration of the gas component for example, hydrogen gas
- the progress of the disproportionation reaction becomes insufficient and the transition metal or transition metal Compound-based magnets The effect of further miniaturization of microparticles is reduced, and radio wave absorption characteristics deteriorate (especially, Lower).
- the volume concentration of the gas components serving as the oxygen, boron, carbon, silicon, and nitrogen component sources in the disproportionation reaction process or the separately performed atmospheric heat treatment becomes less than 1% by volume, the rare-earth oxide Insufficient formation of phase and transition metal compound-based magnetic fine particles may lead to deterioration of absorption characteristics due to eddy current loss.
- the processing temperature of the disproportionation reaction be set at room temperature or higher and 1000 ° C. or lower. Even when the treatment temperature is set to room temperature, each constituent component of the scrap is converted to a fine metal hydride by a preliminary disproportionation reaction based on hydrogenation as a heat treatment in a hydrogen-containing atmosphere before the disproportionation reaction treatment. By decomposing it into a metal and alloy particle phase, the rare earth metal component can be easily converted into a rare earth oxide, and effective development of radio wave absorption characteristics can be promoted.
- the disproportionation reaction treatment temperature is set to 20 when the processing temperature is normal pressure.
- the temperature it is desirable to set the temperature to 0 ° C or higher and to room temperature or higher in the case of high pressure.
- the average particle size of the transition metal-based magnetic fine particles be 500 nm or less. If it exceeds, the transition metal-based or transition metal compound-based magnetic fine particles may become coarse due to mutual fusion or the like, which may lead to a decrease in radio wave absorption characteristics.
- the average particle diameter of the transition metal-based or transition metal compound-based magnetic fine particles is preferably about 10 nm or more, more preferably 20 ⁇ ⁇ or more. It is better to be less than nm.
- each component of boron, carbon, silicon and nitrogen may be added before or after (or both before and after).
- the treatment temperature should be 100 ° C or more and 100 ° C or less. It is desirable to set to. If the treatment temperature is lower than 10 ° C, the formation reaction of transition metal compound-based magnetic fine particles such as borides, carbides, silicates, and nitrides is insufficient. In some cases, sufficient absorption performance may not be achieved by narrowing the radio wave absorption band. If the processing temperature exceeds 100 ° C., the already formed transition metal-based or transition metal compound-based magnetic fine particles may become coarse due to fusion or the like, which may lead to a decrease in the strength of radio wave absorption characteristics.
- the absorption frequency fr (referred to as resonance frequency) of an electromagnetic wave by a magnetic material is related to the anisotropic magnetic field HA value inherent to the magnetic material by the following equation.
- ⁇ is the gyromagnetic ratio. Therefore, the absorption band of electromagnetic waves of the transition metal-based or transition metal compound-based magnetic fine particles derived from the rare earth-transition metal-based metal or the slag scrap by the disproportionation decomposition reaction or the like is specific to each material composition, structure, shape, etc. Is determined by the anisotropic magnetic field ⁇ ⁇ value.
- Table 1 is a series of transition metals, the values of Eta Alpha and f r alloys and compounds are summarized together with those of Nd 2 F e 14 B.
- Table 1 shows that Nd 2 Fe 14 B, the main constituent phase of Nd—Fe—B magnet scrap So the value of H A is 5. a 3 0 mA / m, the resonance absorption frequency f r becomes 1 9 0 GH z before and after, practically still in until use electromagnetic waves of frequency range far current The stage has not been reached.
- the HA value of a_F e (sphere) easily formed from the Nd_F e- B-based magnet scrap by the disproportionation decomposition is about 0.04 MA / ⁇ , which is around 1.5 GHz.
- the f r value of It acicular a- F e the shape state anisotropy reaches to 0.
- one Fe fine particle phase is included as a scrap constituent component and is alloyed with Co and the like, whereby the absorption frequency shifts to a higher frequency side.
- ⁇ -Fe fine particle phase by heating the ⁇ -Fe fine particle phase in an atmosphere gas containing boron, carbon, silicon or nitrogen as a component,? 6 single metal ⁇ 6—.
- the electromagnetic absorption band of the recycled scrap composite powder can be broadened. It can be extended.
- Ni contained in hydrogen storage alloy scrap represented by MmNi 5 is also By pre-alloying with Nd-Fe-B sintered magnet scrap at an appropriate composition ratio, ⁇ - (Fe, Ni), (Fe, Ni) XB , (F e, N i) X C, or (F e, N i) can be played as a complex powder of the transition metal-based X N and the like or a transition metal compound-based rare earth oxide containing magnetic particles, also various of these such is expected to be as the H a and f r value Hirotai GHz band corresponding electromagnetic wave absorber capacity magnetic material with.
- the transition metal alloy-based magnetic fine particles in which Fe is mainly alloyed with Co and Ni have improved oxidation resistance depending on the transition metal content ratio of Co and Ni.
- the disadvantage that a metal is susceptible to oxidative degradation when used as a radio wave absorbing material can be effectively improved.
- rare earth magnets and magnetic powder for hydrogen storage alloy scrap radio wave absorbers by the following processing operations. That is, one or more of boron, carbon, silicon, and nitrogen contained in the raw material or the atmosphere are mixed into the transition metal magnetic fine particles. Thereby, the anisotropy of the transition metal-based magnetic fine particles is improved, and good radio wave absorption characteristics are realized even in a frequency band of, for example, 10 GHz or more.
- rare earth-transition metal scraps often contain one or more of carbon, silicon, and nitrogen as impurity components in addition to oxygen, but these elements include permanent magnets and hydrogen. It is desirable that the storage alloy does not contain as much as possible.
- Scraps with a high content of these elements were of low value for recycling to permanent magnets and hydrogen storage alloys.
- the inclusion of these elements in the scrap can improve the radio wave absorption characteristics, and the Nd_F, which has conventionally been of low utility value, can be improved.
- e- Low-grade scrap such as B-based sintered magnet grinding waste can be more effectively utilized.
- a part of the rare earth-transition metal intermetallic compound contained in the scrap is replaced with boron, carbon, silicon contained in the scrap during the disproportionation reaction treatment. And at least one or more of nitrogen and nitrogen, or an atmosphere heat treatment separately performed before or after the disproportionation reaction, and hydrogen, boron contained in the atmosphere.
- the rare earth metal component and one of carbon, silicon and nitrogen are not completely oxidized.
- the rare-earth-based compound magnetic fine particles are based on a rare-earth oxide and contain at least one or more of carbon, silicon and nitrogen. It is effective to increase the above-mentioned effect by forming it as a mixture.
- a scrap containing at least one or more of carbon, silicon and nitrogen as an impurity component may be subjected to an oxidation heat treatment as a disproportionation treatment after completion of the heat treatment in an inert atmosphere.
- the transition metal-based magnetic fine particles a part of the rare earth metal component is left in the transition metal-based magnetic fine particles during hydrocracking of the scrap.
- Containing a rare earth-transition intermetallic compound hereinafter referred to as rare earth It is also effective to form them as mono-transition metal fine particles.
- the hydrogen content ratio is set to 1 volume. % or more from 1 0 0 vol%, processing temperature 1 0 0 ° C or higher from 8 0 0 ° C or less, it is desirable to carry out the following atmospheric pressure 1 0 7 P a.
- Transition metal-based magnetic fine particles metal-based magnetic fine particles mainly composed of a transition metal.
- Rare earth-transition metal based magnetic fine particles Metal-based magnetic fine particles mainly composed of transition metal-rare earth intermetallic compounds.
- Transition metal compound-based magnetic fine particles Compound-based magnetic fine particles mainly composed of a compound of a transition metal and one or more of boron, carbon, silicon and nitrogen.
- Rare earth-transition metal compound-based magnetic fine particles Compound-based magnetic fine particles mainly composed of a compound obtained by combining one or more of boron, carbon, silicon and nitrogen with a transition metal containing a rare earth metal.
- Rare earth-transition metal alloys and intermetallic compound scraps can be R, I Fe-B (where R is a rare earth element whose main component is Nd) rare earth magnet scrap.
- R is a rare earth element whose main component is Nd
- the present invention to the material that generates a large amount of scrap, the economic ripple effect of the recycling is particularly remarkable.
- the transition metal-based magnetic fine particles have metallic iron as a main component and are mixed with boron. Such transition metal-based magnetic fine particles have better radio wave absorption characteristics (see Table 1).
- the scrap is composed of a defective ingot, a raw material powder of a sintered magnet that has been oxidized and deteriorated, Sinters that have not shrunk sufficiently or have become significantly deformed and have become unworkable), and have poor properties (those that have not obtained the specified magnetic properties (coercive force, residual magnetic flux density and maximum energy product)), Also, it may include at least one or more of defective processed products (for example, defective products) of the sintered body. Recycling of these scraps as permanent magnets (eg, pound magnets and sintered magnets) has also been considered.
- the conventional methods of recycling sintered magnets have been based on the premise that the scrap itself can be reused as a permanent magnet, although to a lesser extent.
- the scrap in particular, they are extremely brittle in material (even though they are metals), so processing to the desired shape with dimensional accuracy is performed by consumable grinding. I have no choice. More than half of the scrap, which represents about 30% of the total magnet production weight, is actually this grinding dust, which is a major factor preventing scrap recycling of rare earth magnets.
- the grinding waste has been regarded as a “dead” resource as a magnet raw material because it is practically ineffective as a magnet raw material due to the incorporation of grinding fluid and grinder abrasive grains and the progress of oxidation.
- a situation is, as it were, residues generated during ingot melting, and the same applies to slag that should not be considered such as magnetized. Therefore, the only treatment currently performed for these is a wet method in which the scrap is dissolved with an acid to recover rare earth components.However, treatment of a waste acid solution and production and abolition of low-value iron residues are required. It is becoming a major environmental problem.
- the slag (silicon or the like that is a rutupo material) generated during the melting of the ingot and the grinding dust generated during the grinding of the magnet sintered body are also used as high-performance radio wave absorbers.
- the grinding debris is obtained by oxidizing the grinding powder of R'-Fe-B based rare earth magnets by contact with water-based grinding fluid, and using carbon, silicon from the power, the grinding fluid and the grinder abrasive used for grinding.
- at least one type of nitrogen is mixed in, but the inclusion of these components has a beneficial effect on the realization of good radio wave absorption characteristics, as described above, and consequently enhances the utility value as scrap You can do it.
- the rare earth-transition metal alloy scrap is mainly composed of an intermetallic compound having a composition of MmNi 5 (where Mm is a misch metal composed of a mixture of two or more rare earth elements). It can also be made of Ni-based hydrogen storage alloy scrap.
- Mm—Ni-based hydrogen storage alloy is a La Ni 5 type hydrogen storage alloy that uses inexpensive misch metal instead of La-separated rare earth, and is used in portable equipment, emergency power supplies, and hybrid vehicles.
- EV Demand for nickel-hydrogen rechargeable batteries used in automobiles is still strong, so the amount of scrap generated during manufacturing and scrap (full nickel) recovered from used products However, this is the second most common in the field of permanent magnets.
- these scraps can be converted into high-performance radio wave absorbers, and the economic ripple effect of recycling is large. Further, the scrap containing nickel can be recycled by mixing it with R, 1 Fe-B rare earth magnet scrap.
- Figure 1 shows the classification of equipment used according to the frequency of electromagnetic waves.
- FIG. 2 shows the basic structure of the radio wave absorber according to the present invention.
- Figure 3 shows the radio wave absorption characteristics of the Nd-Fe-B sintered magnet grinding dust powder.
- Figure 4 shows the X-ray diffraction pattern of Nd-Fe-B based sintered magnet grinding dust powder.
- A No treatment,
- B Atmosphere, 300 ° C, 3 hours
- Hydrogen 800 ° C, 3 hours, in air, 300 ° C, 3 hours.
- Figure 5 shows the radio wave absorption characteristics of Nd-Fe-B based sintered magnet polishing dust powder oxidized in air at 300 ° C for 3 hours.
- Fig. 6 shows the radio wave absorption characteristics of Nd-Fe-B based sintered magnet grinding dust powder that was hydrogenated and oxidized under hydrogen at 800 ° C for 3 hours and in air at 300 ° C for 3 hours. is there.
- Figure 7 shows the X-ray diffraction pattern of the slag powder generated during the production of the Nd-Fe-B based magnet alloy.
- A No treatment
- B Atmosphere at 300 ° C for 3 hours.
- Figure 8 shows the radio wave absorption characteristics of the slag powder produced during the preparation of the Nd-Fe-B based magnet alloy oxidized at 300 ° C for 3 hours in air.
- FIG. 2 is a cross-sectional view of a radio wave absorber according to the present invention.
- the normalized input impedance Z which looks into the metal plate from the absorber surface, is expressed by the following equation (1). It was obtained from equations 2) and (3).
- the reflection loss (radio wave absorption performance) is determined by Z.
- Z is a function of ⁇ , ⁇ , the wavelength of the radio wave; and the thickness d of the specimen.
- the method for calculating the region satisfying 20 dB is various and complicated. Therefore, from the measurement results of the frequency characteristics of ⁇ and ⁇ , the reflection loss when the thickness of the specimen is changed is calculated using Eqs. (1) to (3), and the radio wave absorber is determined based on this value. Can be designed and manufactured.
- a resin piner such as an epoxy resin is blended and kneaded, for example, in an amount of 5 to 100% by mass, and for example, a sheet or board having a predetermined thickness is formed using a metal plate or the like as a substrate, and this is used as a radio wave absorber.
- the resonance frequency at which the electromagnetic wave is most preferably absorbed depends on the thickness of the radio wave absorber as described above, and the thickness can be adjusted according to the frequency of the desired electromagnetic wave.
- Nd-Fe-B sintered magnet grinding dust powder was prepared as R, Fe-B sintered magnet scrap.
- the above polishing dust powder was subjected to disproportionation treatment at 300 ° C. for 3 hours in the air.
- the average particle size was 61 nm in the case of only the oxidation treatment, whereas the average particle size after oxidation was 51 nm. This is due to the fact that the crystal grains were made finer by the hydrogenation treatment performed before the ordinary disproportionation treatment based on oxidation, and despite the latter diffraction intensity and the smaller particle size, However, there was a tendency for the powder to be rather larger than that of the disproportionation-treated powder due to oxidation.
- a rare-earth metal hydride and a transition metal-based magnetic particle having a highly reactive fine particle diameter can be separately generated, and subsequently, In extreme cases, it is possible to lower the formation temperature of the composite powder of transition metal-based magnetic fine particles and rare earth oxide by oxidation to room temperature.
- oxidation usually required a high temperature, and it was difficult to avoid the transfer of some iron components to iron oxide.
- scrap can be regenerated as a composite powder composed of finer crystal particles, and as described later, a magnetic material for radio wave absorbers with high absorption intensity Recycling into materials becomes possible.
- the manufacturing process of R, -Fe-B-based rare earth sintered magnets and the solid R'-Fe-B-based metal scraps recovered from used products are disproportionated after grinding as described above. treatment or atmosphere heat treatment carried out separately, is effectively decomposed disproportionation into a A_F e fine particles and N d 2 0 3 fine particles.
- Fe 2 B fine particles were generated in addition to the above two phases.
- Fig. 3 shows the radio wave absorption characteristics of the powdered Nd-Fe-B sintered magnet powder without any treatment. According to the results, although this sample could absorb electromagnetic waves over a wide frequency range, all of these reflection losses were low and were not practically sufficient. This is because, as described above, the powder remains mainly the magnetic alloy main phase of Nd 2 Fe 14 B because the disproportionation treatment is not performed, and the resonance frequency for electromagnetic waves expected from this powder is theoretically 190 GHz. Depending on
- the reason for the absorption in such a high frequency range is that the resonance frequency of the spherical Fe is usually 1.5 GHz, and this sample has shape anisotropy. Is considered to have been obtained. This difference in the amount of absorption is thought to be due to the fact that the crystal grains become finer and the eddy current is further reduced by covering with the insulating Nd 2 O 3 , thereby increasing the amount of absorption.
- the radio wave absorber made from the regenerated powder is promising as a radio wave absorber for the high frequency range used in indoor radio LANs and ETC.
- R solid R one F e- B based rare-earth sintered magnet '- F e- B based metal scrub Tsu reproduced from flop, a- F e, F e 2 B and Nd 2 0 3 or alpha-F e, even when using the composite powder consisting of the fine particles of F e 3 B ⁇ beauty N d 2 0 3, the excellent radio wave absorption characteristics over a broad range seen by the thickness of the molded body sample.
- the position of the maximum absorption of the electromagnetic wave has a frequency of alpha - compared to a sample consisting only of F e and Nd 2 0 3, the high-frequency There was a tendency to move to the side.
- Nd_Fe_B-based sintered magnet grinding powder which is an R
- one Fe-B-based sintered magnet scrap a- regenerated by the disproportionation treatment in an oxygen-containing atmosphere.
- the HA value of the obtained composite powder also increased, and the radio wave absorption position shifted to a higher frequency side according to the degree. (Example 2)
- Figure 7 shows the XRD patterns of the untreated and oxidized alloy slags.
- FIG. 8 shows the radio wave absorption characteristics of the epoxy resin-containing molded body manufactured using the above powder. From the figure, it can be seen that by changing the sample thickness from 4 mm to 1.5 mm, the reflection loss of the sample has a good absorption exceeding 20 dB over the range of approximately 5 GHz to 15 GHz. Was seen. From this, it is said that approximately 1% of slag is generated during the production of raw material alloys for manufacturing Nd-Fe-B magnets, and this slag is also a good electromagnetic wave in the high frequency region. It can be seen that absorption characteristics can be exhibited. It was also found that this sample is promising as an efficient absorber for high-frequency electromagnetic waves used in indoor wireless LAN, ETC, satellite broadcasting, etc., where demand is expected to expand in the future.
- nickel-hydrogen rechargeable batteries are recycled in the form of nickel in the Hue mouth through pack disassembly, crushing, sorting, and roasting processes, and are used as raw materials for stainless steel. Therefore, after the metal scrap contained in the nickel-hydrogen secondary battery recovered after the crushing and sorting is washed, and mixed with a predetermined amount of the powder of the R′—Fe—B based rare earth sintered magnet, 80 After hydrogen reduction at 0 ° C, heating was performed at around 110 ° C. This is milled and then subjected to the disproportionation reaction treatment or the atmosphere heat treatment performed separately therefrom, which is effective for a— (F e, Ni) fine particles and R 2 O 3 fine particles. Not It was leveled.
- Regenerated composite powder, R one F e- B based rare-earth sintered in sintered magnet powder scrap derived from alpha-F e fine particles and N d 2 0 3 a fine particle composite powder ratio Baie, absorption frequency Despite shifting to the lower frequency side, it exhibited good absorption characteristics for the most envisioned electromagnetic waves up to 10 GHz.
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
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US9044834B2 (en) | 2013-06-17 | 2015-06-02 | Urban Mining Technology Company | Magnet recycling to create Nd—Fe—B magnets with improved or restored magnetic performance |
US9336932B1 (en) | 2014-08-15 | 2016-05-10 | Urban Mining Company | Grain boundary engineering |
CN114006002A (zh) * | 2021-10-28 | 2022-02-01 | 华能国际电力股份有限公司 | 一种熔融碳酸盐燃料电池中金属镍的回收方法 |
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JP5273241B2 (ja) * | 2009-02-27 | 2013-08-28 | 国立大学法人大阪大学 | Re−tm系混合物からの希土類元素の回収方法 |
CN102560422A (zh) * | 2011-12-23 | 2012-07-11 | 嘉兴科民电子设备技术有限公司 | 多片远程等离子体增强原子层沉积腔室 |
US10081040B2 (en) | 2012-12-26 | 2018-09-25 | Hitachi Metals, Ltd. | Method for recovering rare earth element |
JP6264195B2 (ja) * | 2014-05-27 | 2018-01-24 | 日立金属株式会社 | 希土類元素の回収方法 |
JP6413877B2 (ja) * | 2014-03-28 | 2018-10-31 | 日立金属株式会社 | 希土類元素の回収方法 |
CN106133157A (zh) * | 2014-03-28 | 2016-11-16 | 日立金属株式会社 | 稀土元素的回收方法 |
CN104232905B (zh) * | 2014-06-16 | 2015-08-12 | 赣州力赛科新技术有限公司 | 一种含有高价值元素氢氧化铁基原料及其用途 |
JP6406172B2 (ja) * | 2015-08-25 | 2018-10-17 | 住友金属鉱山株式会社 | 希土類元素を含む鉄系合金微粉末の製造方法 |
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US9044834B2 (en) | 2013-06-17 | 2015-06-02 | Urban Mining Technology Company | Magnet recycling to create Nd—Fe—B magnets with improved or restored magnetic performance |
US9067284B2 (en) | 2013-06-17 | 2015-06-30 | Urban Mining Technology Company, Llc | Magnet recycling to create Nd—Fe—B magnets with improved or restored magnetic performance |
US9095940B2 (en) | 2013-06-17 | 2015-08-04 | Miha Zakotnik | Harvesting apparatus for magnet recycling |
US9144865B2 (en) | 2013-06-17 | 2015-09-29 | Urban Mining Technology Company | Mixing apparatus for magnet recycling |
US9336932B1 (en) | 2014-08-15 | 2016-05-10 | Urban Mining Company | Grain boundary engineering |
US10395823B2 (en) | 2014-08-15 | 2019-08-27 | Urban Mining Company | Grain boundary engineering |
US11270841B2 (en) | 2014-08-15 | 2022-03-08 | Urban Mining Company | Grain boundary engineering |
CN114006002A (zh) * | 2021-10-28 | 2022-02-01 | 华能国际电力股份有限公司 | 一种熔融碳酸盐燃料电池中金属镍的回收方法 |
CN114006002B (zh) * | 2021-10-28 | 2023-05-16 | 华能国际电力股份有限公司 | 一种熔融碳酸盐燃料电池中金属镍的回收方法 |
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