An environmental-friendly alternative to recovery Rare Earth Elements from spent NdFeB permanent magnets by electrochemical recycling process

The European Union (EU) has the ambitious target to reach net zero greenhouse gas emissions by 2050.

The current energy transition is playing a crucial role in achieving a greener future by electrification of industries and the use of renewable resources for energy.

Many greener applications rely on electric motors or generators that contain NdFeB permanent magnets (PM) in large quantities. The composition of these magnets is about 30 % of rare-earth elements (REEs), mainly neodymium (Nd). The worldwide supply of REEs is controlled by China (85 %).

As the demand of REEs is increasing, due to energy transition, it is important for the EU to ensure a continuous supply of REEs. Recycling end-of-life magnets is a feasible alternative to obtain REEs from secondary resources.

With REEcycle research project, my objective is to determine, for the first time, the leaching mechanism of REEs in NdFeB magnet scrap, aiming at selective recovery of REEs by means of electrochemical leaching in organic acids.

I will combine different electrochemical approaches at different scales to evaluate the electroleaching efficiency in organic acids aiming at the selection of the most suitable acid and process conditions for a high dissolution rate of REEs.

Then, to determine the leaching mechanism under electrochemical effect, I will use a recently developed local electrochemical technique, scanning electrochemical cell microscopy (SECCM), which will indicate the dissolution parameters for each element present in the NdFeB matrix.

Finally, with the findings from SECCM, I will be able to promote a controlled electroleaching in organic acid followed by oxidation of Fe2+, to selectively recover the REEs from the magnet scrap.

With my project, the use of organic acids and an electrochemical approach will bring the realisation of a sustainable recycling of permanent magnets a step forward, thereby contributing to the EUs knowledge in REE supply from secondary sources.