Sourcing, Refining and Recycling of Rare-Earth Magnets

Abstract

Permanent magnets today are used in a wide range of transportation, industrial, residential/commercial, consumer electronics, defense, domestic, data storage, wind energy, and medical markets and applications. There are five classes of commercial permanent magnet materials; however, magnets based on Nd-Fe-B account for over 60% of the global magnet production by value. They typically contain around 31 wt.% of rare earth elements (REEs), principally, Nd and Pr, plus Dy for higher-temperature performance. Nd-Fe-B magnets are forecast to grow throughout this decade, largely driven by the growth in electric vehicles of all types. However, several studies forecast a shortfall of the primary REEs from mined resources. In this paper, the sourcing, processing, and recycling of REEs are discussed. Additionally, presented are the advantages and disadvantages of the major recovery and recycling technologies for REEs.

Commercial-Scale Modification of NdFeB Magnets under Laser-Assisted Conditions

“…Their utility is diverse as they can be tailored in terms of both shape and geometry. Nevertheless, obtaining materials for manufacturing magnets from rare earth elements is not only a demanding process but is also costly and time consuming [ 3 , 4 , 5 , 6 , 7 ].…”

“…The search for solutions to increase this level of protection using different magnet coatings has been performed in many studies [ 3 , 4 , 8 , 9 , 10 ]. Among the most commonly used coatings are Ni-Cu-Ni, Zn, Rubber, Au, PTFE, Cr, and Ti Nitride [ 5 , 6 , 7 , 8 , 9 , 10 ]. Coating manufacturing methods include the best-known example, based on electrochemical processes [ 8 ], or otherwise surface polishing by industrial robots and cold-sprayed coatings used for smaller scale [ 7 , 11 , 12 , 13 , 14 , 15 ].…”

The Impact of Plasma Surface Treatments on the Mechanical Properties and Magnetic Performance of FDM-Printed NdFeB/PA12 Magnets

“…Permanent magnets, especially those based on rare earth materials, are crucial in modern high-technology applications and their integration into electronics and renewable technologies has become increasingly widespread in daily life [1]. As the demand for such materials increases, the sustainable use of rare earth elements, which are recognized as critical raw materials, is essential [2].…”

A Simple Supramolecular Approach to Recycling Rare Earth Elements

“…Several processes have been developed for the direct recycling of EOL REE-containing magnets through hydrogen processing or mechanical separation routes. − These processes minimize some of the costs and waste associated with metal recovery but require careful dismantling steps and predominantly single-source waste streams . The majority of REE waste is present in the form of shredded material, where, among other reasons, the vast array of other metallic impurities often preclude direct recycling methods.…”

“…8−11 These processes minimize some of the costs and waste associated with metal recovery but require careful dismantling steps and predominantly single-source waste streams. 12 The majority of REE waste is present in the form of shredded material, where, among other reasons, the vast array of other metallic impurities often preclude direct recycling methods. As such, developing methods for the recovery of REEs from these waste streams is critical.…”