New recycling process for neodymium-iron-boron magnets

The reprocessing of end-of-life magnets made of rare earths was not considered for a long time. Increasing world market prices, the strong dependence on a few exporters and the increasing demand have led to a shift in thinking. However, until now magnets have been recycled in complex chemical processes. Together with the Fraunhofer Institute, Heraeus has developed a new recycling process. This allows neodymium-iron-boron magnets to be reprocessed in a more environmentally friendly way.

Using pyrometallurgical processing of old permanent magnets, Heraeus Remloy has developed a new process for the recycling of sintered magnets. It means that sintered magnets from, for example, electric motors, medical equipment or hard drives are melted down to produce new alloys. This process is suitable for all neodymium-iron-boron magnet compositions.

Eco-friendly process

• No electrolysis and no chemicals required
• 80% energy / CO₂ savings
• Low logistic effort: supply chains within Europe

The end-of-life magnets are melted down, resulting in  neodymium-iron-boron materials that are used to produce plastic-bonded or hot-formed magnets.

This is in contrast to the wet chemical process, where the end-of-life magnets are dissolved, the metals separated, and then reconverted to metal alloys. These alloys are used to create the metal powders. The process is more time consuming, very energy-intensive and has a strong environmental impact.

 Please contact us for the processing of your end-of-life magnets.

The recycling of permanent magnets is one of the methods to ensure a European supply of magnet material. In Europe, rare earths such as neodymium, from which permanent magnets are made, are almost not mined at all. Most rare earths are mined in Asia. The world market is dominated by China. However, forecasts predict that China will consume its entire production of neodymium on its own. Due to the high demand for the materials, also as a result of the energy transition, the availability of these raw materials may quickly become scarce.

Rare earths are therefore considered by the European Union to be critical raw materials, and material supply streams are to be diversified. Recycling plays a crucial role in this process, as economically rewarding extraction sites are cost-intensive and entail ecological consequences. Heraeus Remloy was supported by the European Regional Development Fund (ERDF) as part of a funding program for "Model Research and Development Projects for CO2 Reduction". The reprocessing of end-of-life magnets by Heraeus supports the "Green Deal" of the European Union.

Global demand for rare earth oxides is expected to reach almost 190,000 tons in 2030. In particular, rare earths for permanent magnets - neodymium, praseodymium, dysprosium and samarium - will be increasingly required in the near future. These elements are essential for the production of rare-earth magnets. Neither the mobility revolution nor the expansion of renewable energies will be possible without powerful magnets. Consumer electronics, medical technologies and science are also completely dependent on neodymium magnets.

 Learn more about the neodymium-iron-boron materials we offer as a reliable partner.

The EU has identified the importance of rare earths and the products derived from them. The supply of rare earths is prioritized because they are among the raw materials with the highest supply risk. This is also due to the fact that there are almost no mines for rare earths in Europe. In contrast, China covers almost 90 percent of global production. At the same time, demand for rare earths and especially permanent magnets is also increasing in China. Export restrictions are therefore a serious risk.

By reprocessing end-of-life magnets, Heraeus Remloy offers a solution for an alternative source of supply. For the first time, a material supply chain for neodymium-iron-boron magnets can be established in Europe. European companies can thus not only obtain a reliable source for their permanent magnet needs, but also increase the sustainability of their product manufacturing.