To alleviate the pressure on the rare earth supply chain, new technologies are under development for recovering, recycling and remanufacturing NdFeB magnets. In this study, the anticipated... Show moreTo alleviate the pressure on the rare earth supply chain, new technologies are under development for recovering, recycling and remanufacturing NdFeB magnets. In this study, the anticipated environmental performance of large-scale recycling is investigated and compared to the production of primary magnets. To do so, this ex-ante life cycle assessment combines input from measurements of pilot processes, expert technology forecasts, thermodynamic modeling, and equipment data from manufacturers. We examined the effect of four technology developments: process changes, size scaling, internal recycling, and optimization. The results show that at pilot scale, recovered NdFeB powders have lower impacts than primary powders for almost all impact categories. This demonstrates that the recovery of NdFeB alloys is environmentally beneficial. Magnets from anticipated large-scale recycling have over 80% lower impacts than primary magnets in most of the impact categories analyzed. All four investigated types of technology development contributed to this improved performance. The final configuration was validated by comparison with an industrial reference and theoretical optimum configuration. Four magnet manufacturing routes (sintering, extrusion, metal injection molding, bonding) have distinct environmental profiles, but all can progress to similarly low levels of impact. The choice among routes should be primarily based on the functional requirements. Show less
The rare earth magnet market experiences serious turmoil: prices fluctuate heavily while the demand is growing exponentially driven by wind turbines and electric vehicles. Recycling helps to reduce... Show moreThe rare earth magnet market experiences serious turmoil: prices fluctuate heavily while the demand is growing exponentially driven by wind turbines and electric vehicles. Recycling helps to reduce the pressure on rare earth mining, while presenting a solution for growing waste flows. While the development of recycling technologies is ongoing, we investigate the further development of short-loop recycling from small scale to industrial scale. This ex-ante LCA study combines input from expert technology forecasts, thermodynamic modelling, manufacturer data for equipment, and energy scenarios. Our approach systematically considers all mechanisms for performance changes when upscaling, from size scaling to decarbonizing electricity. The results show the effect of process design choices and the effect of end-of-life product inputs. Moreover, the assessment of multiple process improvements leads to an outlook of potential development pathways towards low-emission magnet recycling. Our systematic approach, which involves the active participation of technology developers, can be extended to support the upscaling of other emergent technologies. Show less
