REEs & COBALT SUSTAINABLE SUPPLY FROM MAGNET RECYCLING: Closing the loop
DysCovery is at the forefront of advancing sustainable practices through the scale-up of innovative recycling processes for End-of-Life (EoL) permanent magnets. This project focuses on three key processes: a hydrogen-free leaching process, extraction chromatography metal separation, and metal/alloy production. The aim is to establish a cutting-edge recycling facility capable of processing 630 tons per annum (t/a) of EoL material, significantly bolstering the European Union’s (EU) recycling capacity by a minimum of 23%.
Key Highlights of DysCovery’s Recycling Initiative:
Hydrogen-Free Leaching Process: DysCovery incorporates a patented hydrogen-free leaching process, ensuring an environmentally friendly approach to metal recovery. This method contributes to the circular economy by efficiently extracting valuable critical metals from EoL permanent magnets.
Extraction Chromatography Metal Separation: The project integrates an extraction chromatography metal separation process, allowing for precise and efficient separation of metals. This technological advancement enhances the purity of the recycled materials, meeting stringent quality standards for magnet production.
Metal/Alloy Production: DysCovery’s facility is equipped for metal/alloy production, resulting in high-quality magnet-specification metals. These metals, in total 300 t/a, will be commercialized at a remarkable 30% lower than current market prices, positioning them as cost-effective solutions for various applications, particularly in the e-mobility sector.
Non-flammable pre-processing: The technologies encompassed within DysCovery Initiative tackle the safety issues that arise from the magnets flammability during preprocessing by adopting innovative approaches for safe and cost-effective handling.
E-mobility Application Testing: The magnet-specification metals produced by DysCovery will undergo rigorous testing in the manufacturing of NdFeB/SmCo magnets. These magnets are specifically tailored for e-mobility applications, contributing to the advancement of sustainable and energy-efficient transportation.
Market Impact and Cost Competitiveness: DysCovery’s efforts not only contribute to environmental conservation but also have a direct impact on market dynamics. By offering recycled metals at a significantly reduced cost (30% lower than current market prices), the project sets new standards for cost competitiveness in the recycling and magnet production sectors.
DysCovery is committed to pushing the boundaries of innovation and sustainability in recycling magnets process, contributing to a circular economy, and ensuring a greener future for the EU.
DysCovery represents a significant contribution to the European Union (EU), the European Raw Materials Alliance (ERMA), and the European Battery Alliance (EBA). This initiative aligns with the strategic goal of meeting the increasing demand for critical metals such as Nd, Pr, Dy, Sm, and Co.
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These metals are currently reliant on imports from China in refined or finished product forms. DysCovery addresses this dependency by establishing a recycling pathway for these metals within Europe, particularly sourced from End-of-Life (EoL) magnets.
Key Contributions of DysCovery:
ERMA Task Force Action Plan: The ERMA Task Force on permanent magnets and motors has formulated an ACTION PLAN to elevate the permanent magnet recycling capacity in the EU. Presently at 500 t/a, the goal is to reach 7000 t/a by 2030. With current projects, the recycling capacity is projected to be around 1500-2000 t/a by 2025. DysCovery significantly contributes to this plan by establishing a 630-ton capacity recycling plant for permanent magnets and related materials at MONOLITHOS in Greece. This project alone is projected to increase the EU’s recycling capacity by a minimum of 23% by 2030.
Material Sourcing and Collaboration: DysCovery collaborates with local governments and engages with the car and wind energy sectors, such as turbines, to collect materials for recycling. Scrap and swarf from EU magnet producers also contribute to the raw materials for the project. This collaborative effort ensures a sustainable supply chain for critical metals.
Circular Production Model: MAGNETI, based in Ljubljana, Slovenia, aims to enhance its magnets production business chain sustainability by incorporating up to 50% recycled material in the production process of NdFeB and SmCo magnets.
DysCovery plays a pivotal role in achieving this goal by upscaling three innovative technologies to Technology Readiness Level (TRL) 8:
Hydrogen-free metal leaching patented by MEAB (Germany).
Extraction chromatography metal separation upscaled by KTH (Sweden).
Nd and NdPr/NdDy alloy production through molten salt electrowinning by TUBAF (Germany).
DysCovery is not only addressing the immediate challenges of material dependency, but also fostering a sustainable and circular approach to production processes, contributing to the EU’s strategic goals in the raw materials sector.
