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WELCOME TO THE REEPRODUCE NEWSLETTER |
Our journey started in May 2022, and since then, we have welcomed numerous visitors to our channels who have been following our project’s journey. Thank you!
Today we are excited to present the third edition of our newsletter. Our mission is to keep you informed about our latest developments. For this reason, we are thrilled to announce the release of the first video of the REEPRODUCE project!
Join us in exploring the essence of the project and the initial strides taken by our consortium. Dive into the core of our project and let’s embark on this exciting journey together! |
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Project progress so far |
Revolutionising small-scale magnet recycling: optimising Nd-based extraction |
| Over the last two years, Institute FAPS of the Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU) has developed corresponding process chains for relevant end-of-life (EOL) products containing RE-based magnets. |
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As a first step and based on relevant characteristics - such as rare-earth (RE) content, product volume, product variance and dismantlability – the REEPRODUCE consortium has selected three representative applications to demonstrate the processing of EOL motors: automotive traction drives, traction drives from e-scooters, and hoverboards and HVAC compressors.
Due to individual characteristics of the rotors from these applications, specific process chains and machineries are required in each case, which are currently under development at FAU. In this framework, the focus of development is set on the processing of already extracted permanent magnets (PM) rotors. Although various process alternatives have been considered, in general, the process chain for each application compromises the single steps: sorting, handling, thermal demagnetisation, rotor dismantling and ejection of the magnets. After initial trials based on representative rotors provided by the partners, FAU initiated the demonstration of the selected processes at laboratory scale. As a next step, they will transfer their internal prototype machinery to the near-series demonstration made by partner Bronneberg. These final pilot machines are disassembly lines including several stations. |
In this context, CEIT has developed an intelligent robotic system guided by vision and able to dismantle the HDDs and other electronic devices supplied by Indumetal in order to recover components with RE magnets. As a result, only the magnets and the iron yokes are entering the process. Additionally, for the extraction of the RE magnets, FAU has developed a separation and sorting system. Thus, all steps are connected by a conveyor belt so that the entire process runs as a continues flow process.
The first step of the process implies magnets to be heated up to a temperature above the specific Curie temperature. Consequently, based on a mechanical principle used for pre-sorting to ensure a high throughput, the adhesive bond between the magnets and the iron yokes are destroyed permitting the separation of the different parts. |
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Thermal demagnetisation by induction |
Moreover, based on an extensive catalog of geometric features for the input material, a sorting drum has been developed allowing a continuous process flow. Nevertheless, currently the mechanical sorting based on geometry is not completely reliable and, consequently, FAU has integrated a ,magnetic sorting system. In addition, a robot in combination with vision system for resorting is being investigated. The overall system is currently under construction.
The last and more challenging route deals with the sorting of shredded EOL products since the scrap is a material mix of various components with a very low concentration of RE magnets. In the current scenario, high-performance systems that separate ferrous metals, non-ferrous metals and plastics are already in place at most of the recycler's facilities. The input material for the new process is the ferrous fraction, which contains the RE magnets. However, as a constraint, the soft and hard magnetic components of these fractions have very similar physical properties. Thus, for the extraction of neodymium magnets (NdFeB) a sequential sorting process is under investigation. FAU has done preliminary tests showing that pre-sorting is possible only based on mechanical properties, but the material obtained in this way must be further purified. At present, to separate the NdFeB fraction, FAU is carrying out experiments using also the magnetic properties. Furthermore, FAU is also investigating the sorting principles for the removal of other relevant types of magnets such as hard ferrites, SmCo and AlNiCo. |
How is REEPRODUCE optimising the Advanced Hydrometallurgy for Rare-Earth Oxides production? |
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How are you optimising the Advanced Hydrometallurgy for Rare Earth Oxides production?
Tecnalia manages the design and optimisation of the laboratory scale chemical process to extract the rare earths from neodymium magnets and their transformation into high purity rare earth oxides (REO), which will be the input of subsequent high temperature electrolysis process to produce magnet alloys.
The focus of the optimisation of the Advanced Hydrometallurgical process is to achieve a flexible process which can be applied to different chemistries of spent neodymium magnets achieving high REO purities, regardless the source and specific composition of the magnets. |
What are the main challenges you have faced?
The variability of the input magnet composition and the removal of some impurities which are detrimental for the subsequent electrolysis step are our main challenges. Additionally, achieving the specific objective of a REE recovery of more than 95% in a process designed in five steps, for which all the steps are expected to have yields close to or higher than 99%, has been demanding. Tecnalia is addressing such challenges by performing chemical analysis and mass balances during the development of the process and investigating different purification strategies to reach the highest REO purity possible.
In the REEPRODUCE project's context, what is this activity's goal?
Developing a laboratory scale chemical recovery process able to produce high purity REOs with high efficiency and, at the same time, able to be upscaled and meet the production goals of the REEPRODUCE project. For the latter objectives, Tecnalia is also supporting in addressing the problems that arise in the early stages of scaling up.
What are your ambitions in contributing to stimulate a more sustainable Europe raw material value chain?
At Tecnalia, our main driver is developing solutions that can contribute to a more sustainable use of the raw materials, ensuring their circularity as well as their availability for Europe. |
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Get ready to be inspired as we unveil the fascinating stories behind our incredible partners. In this “partners’ corner” we explore their roles in the framework of the REEPRODUCE project and bring you exclusive interview packed with valuable insights. |
Bronneberg’s as key player in the global recycling equipment market |
| In the context of the REEPRODUCE project, what is Bronneberg’s goal?
From its very creation in 1946 Bronneberg has been active in the recycling industry so definitely no secrets here. It is our goal to keep following in this field as continuously new challenges are appearing on our route. |
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FAU has optimised the Nd-basedextraction. Based on these results, how is Bronneberg going to step forward?
The very first hurdle was to select the rightas well as available components containing Neodymium (Nd) magnets and determiningwhere to find them. Most obvious this appeared to be the normal E-motoranchors. Only very specific E-motors contain Nd-magnets however it is verycomplicated to recognise and thus select. |
What are your reflections on the outcomes, and how do you see their significance for your role within the project?
We now begin seeing a clear direction on how to proceed. As from now we will continue full force to finalise the idea of the engineering design and followed by building the different prototypes. |
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What are your reflections on the outcomes, and how do you see their significance for your role within the project?
We now begin seeing a clear direction on how to proceed. As from now we will continue full force to finalise the idea of the engineering design and followed by building the different prototypes.
How Bronneberg’s competence in recycling machines contribute to the REEPRODUCE project? |
| Bronneberg recycling machines do not have a lot in common with the design idea we now have with regards to the Nd-magnet dismantling lines. It was though one of our machines, the E-motor wrecker, that is relevant in the REEPRODUCE project. Our large and relevant experience in developing different machines is indeed instrumental to succeed achieving the objectives of the project. |
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What are your ambitions in contributing to stimulate a more sustainable Europe raw material value chain?
Designing, manufacturing and supplying equipment to the recycling industry has been and most possibly will remain our main activity since the very beginning. The recovery of Nd-magnets will definitely widen our view in this particular field. Since our start in the REEPRODUCE project we have already learned that in the general the recycling industry is not aware at all of the importance of the Nd-magnet recovery and of this important value chain. There is still a lot of progress to be made in this regard and we will continue to support this with all our strength. |
Revolusionising recycling: JGI-HYDROMETAL innovative solutions for non-ferrous metals |
| What is the goal of the JGI-HYDROMETAL group in the context of the REEPRODUCE project?
JGI-HYDROMETAL aims at upgrading its expertise in the recycling of rare earths from waste and by-products. This know-how has been gained since 2010 when the company expanded its business lines to the recycling of these critical metals from polishing sludges and magnet swarf. |
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The company decided to partner with Research & Innovation (R&I) entities in this project to develop innovative solutions that tackle the complex chemistry of the incoming wave of permanents magnets extracted from a variety of EOL products.
TECNALIA has been optimising its innovative Advanced Hydrometallurgy (AHM) technology to extract and recover rare earths. How is JGI-HYDROMETAL going to step forward?
Given our role as operators and validators of the AHM pilot, JGI-HYDROMETAL has been using its expertise in industrial recycling of non-ferrous metals to guide the R&D phase of the AHM technology as well as the engineering of the AHM pilot.
Can you briefly explain the process to recover rare earths from end-of-life Nd-based permanent magnets to yield high-quality REEs-oxides? |
In a general perspective, the AHM technology is based on hydrometallurgy in acidic medium to dissolve the rare earths (together with impurities), followed by purifications and conversion steps to finally recover the target as a mixture in oxide form. |
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What are your reflections on the outcomes, and how do you see their significance for your role within the project?
The role of JGI-HYDROMETAL in the project, i.e., the demonstration of the successful extraction and recovery of rare earths from end-of-life permanents magnets (by the AHM technology) is significant to take a leading role in unlocking businesses in the rare earths recycling value chain, connecting WEEE collectors and recyclers (managing magnets) with downstream rare earths refiners, producers, and rare earths-intensive products.
What are your ambitions in contributing to stimulating a more sustainable European raw material value chain?
JGI-HYDROMETAL has been committed to leading the non-ferrous metals industry towards sustainable development. In the case of rare earths, the company sees this ambition through its contribution to reducing the loss of these metals in waste streams (such as in European EoL products bearing permanent magnets) as well as in unlocking and controlling the access of these critical metals from European secondary sources. |
REEPRODUCE HIGHLIGHTS |
 | The REEPRODUCE External Advisory Board (EAB) met online for the first time on 13 September 2023. The EAB members provided predominantly positive feedback regarding the clarity of the REEPRODUCE project's objectives. They engaged in a dialogue addressing the potential opportunities and challenges associated with recycling in Europe.
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|  | From 13 to 14 December 2023 the REEPRODUCE consortium gathered at Indumetal Recycling in Bilbao (Spain) where the REEPRODUCE’s Intelligent Sorting Pilot has been installed to commencing working on the sensing, identification and separation of EOL products containing PMs at the recycles premises.
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REEPRODUCE PRESENCE AT…! |
 | Raw Materials Week 2023!
The REEPRODUCE project participated in the SUSMAGPRO final event during the Raw Material Week organised by the European Commission in Brussels from November 13to 17, 2023.
During the session titled “REEsilience and REEPRODUCE – Dealing with scrap: Automated sorting and separating line for magnets from end-of-life products”, Dr. Nina Dahl, Researcher Director at SINTEF Industry presented the innovative solution of the project on behalf of the Coordinator, as well as the work done so far. | |
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Tomasz Filipów (CEO, ProDevice) gave a presentation about Innovation on Rare Earth Recovery and showcased how the REEPRODUCE project is currently developing to establish the first sustainable and compete European REEs-recycling value chain at industrial scale.
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 | 13th Congress of the German Academic Association for Production Technology
FAU presented a scientific paper on “Approach for Advanced Mechanical Recycling Strategies of Rare Earth Magnets Applied in Traction Drives”. The publication presents the recovery of SE magnets from automotive traction drives. | |
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