As the demand for electric vehicles (EVs) and renewable energy technologies continues to grow, so does the need for rare earth elements (REEs), essential components in high-performance magnets. However, the global supply of these critical materials is often constrained by geopolitical, economic, and environmental challenges.
To address this Ionic Technologies, Less Common Metals (LCM), and Ford have joined forces to develop a 100% recycled rare earth magnet supply chain in the UK. This project aims to establish a demonstration-scale circular economy model for REEs, reducing reliance on virgin materials and minimising environmental impact.
In this Q&A, we speak with LCM’s Senior Development Metallurgist to explore the technical innovations, challenges, and long-term implications of producing high-specification magnets from recycled REEs.
What is your position? How are you involved in the project?
As the Senior Development Metallurgist at LCM, I focus on optimising alloy production from secondary rare earth oxide feedstock. My role involves process improvements to enhance efficiency and quality in rare earth metal production, ensuring that the alloys used in permanent magnets meet the stringent performance standards required for Ford’s E-Drive motor.
What is the primary goal of the project?
Ionic Technologies, Less Common Metals (LCM), and Ford aim to establish a demonstration-scale circular supply chain for Rare Earth Elements (REEs) in the UK. This initiative will utilise innovative technologies to produce high-specification magnets for electric vehicles (EVs) using 100% recycled REEs.
What is LCM’s role in the project?
LCM will conduct the metallisation process, converting rare earth oxides recovered from spent magnets by Ionic Technologies into high-purity rare earth metals such as neodymium-praseodymium (NdPr), terbium (Tb), and dysprosium (Dy).
These metals will be strip cast into alloys that meet the specifications required for magnets and will then be supplied to a subcontracted magnet manufacturer. The resulting recycled permanent magnets will be integrated into Ford’s E-Drive motor system.
What are the technical challenges of creating high-specification magnets with 100% recycled REEs?
Recycled REEs must achieve a purity of over 99.5% to ensure high-performance magnets, as even small contaminants can degrade their properties. One of the key challenges lies in material recovery efficiency, where achieving both high yield and purity in separation and refining, particularly in solvent extraction, remains complex.
Consistency in alloy production is also critical, as variations in REE metal and alloy composition can directly impact magnet performance. Additionally, maintaining essential magnetic properties such as coercivity, remanence, and energy product is crucial to ensure recycled materials match or exceed the performance of virgin REEs.
How will the recycling process ensure that the magnets meet the performance standards required for electric vehicles (EVs)?
The expertise of all project partners will be leveraged to monitor material purity and quality at every stage of the supply chain. Data from virgin materials will serve as a reference to benchmark the specifications of recycled materials and predict final product performance. Additionally, a closed-loop recycling system will be implemented, ensuring that any swarf or process waste generated is reintegrated, minimising material losses.
How will the project impact the supply chain resilience of rare earth materials in the UK and globally?
This project will significantly enhance the resilience of the UK’s REE supply chain by reducing import dependency and establishing a domestic, circular supply chain. By securing a stable and localised source of recycled REEs, it mitigates risks associated with geopolitical uncertainties, while also reducing environmental impact.
Additionally, the project supports the UK’s Net Zero target by ensuring a reliable and sustainable supply of REEs for the expanding electric vehicle (EV) and renewable energy sectors. Its success at the demonstration scale could serve as a catalyst for future investment in commercial-scale REE recycling facilities, further strengthening the UK’s supply chain independence and positioning it as a key player in the global REE supply network.
Are there plans to scale up the project beyond the demonstration phase, and what would this entail?
Yes. The outcome of this project is intended to establish a foundation for the future expansion of the recycled REE supply chain model in the UK.
WSP has recently completed a feasibility study for Ionic Technologies, focusing on designing a commercially viable production facility for rare earth oxides through permanent magnet recycling.
In parallel, LCM has been commercially producing Nd, NdPr, Dy and Tb metals using molten salt electrolysis and metallothermic processes since 2017, meeting the requirements of the Western World. The proof-of-concept developed through this project could encourage magnet production companies to expand and invest in the UK, which currently lacks such investment. By fostering collaborations with end-users and OEMs, such as Ford, we can build a strong foundation for the recycled REE supply chain within the UK and the broader Western world. Additionally, government support will be crucial for commercial viability, as one of the main challenges within the supply chain is the need to remain cost-competitive.
How will the project address potential technical limitations in recycling REEs?
The project addresses potential technical limitations in recycling REEs by employing several key strategies to ensure high-performance magnets. Ionic Technologies patented solvent separation method, using ionic liquid additives, enables efficient processing of individual REOs with fewer separation stages and reduced reagent consumption while maintaining high purity.
LCM’s expertise in alloy production ensures that recycled REEs maintain consistent quality, meeting the stringent requirements for permanent magnets. To validate performance, recycled permanent magnets will undergo real-world testing in Ford’s EV motors, allowing for the identification and resolution of any performance gaps. Additionally, insights from the demonstration phase will drive process improvements, facilitating a smooth transition to commercial-scale production.
If successful, this initiative could pave the way for larger-scale commercial recycling of REEs, strengthening domestic supply chains and reinforcing the UK’s position as a leader in sustainable magnet production. As advancements continue, collaboration between industry, government, and research institutions will be key to unlocking the full potential of recycled REEs in the global market.