Industrial Production of mixed Rare Earth Elements oxides and carbonates from spent magnets recycling

Introduction

The overall objective of the “close to the market” LIFE INSPIREE project is to realize the first industrial-scale plant in Europe for the recycling of REEs from spent NdFeB magnets (Hard Drives (HDD) and End-Of-Life electric motors). INSPIREE will build on the results achieved at pilot scale of previous EU funded projects (EITRM-NEWRE, H2020-FENIX, and FP7-HydroWEEE).

Patented Process

The hydrometallurgical process has been patented by one of the partners (WO/2019/215583A1) and this strategic know-how was transferred to Itelyum during the previous research-pilot phase.

Process Development

A two-level process will be developed for:

1. Permanent magnets disassembly (Level I)
2. REE oxalates recovery by hydrometallurgy (Level II)

Level I Plant

The Level I plant at Globeco will have a final workable capacity of 1000 t/y in terms of electric rotors disassembly.

Level II Plant

The Level II plant at Itelyum has a full-scale capacity of 2000 t/y in terms of incoming NdFeB PMs, thus enabling – in perspective – the recovery of about 700 t/y of REEs.

Technical and Environmental Advantages

The hydromet process shows important technical advantages with respect to state-of-the-art techniques, but more importantly, it offers significant environmental improvements in terms of chemicals and water reuse.

Commercial Exploitation

Output materials, REE oxides, and carbonates will be possibly exploited commercially already before the end of the project, thanks to the collaboration with major players in Italy and Europe.

Economic Sustainability

A rather detailed Business Plan that demonstrates the economic sustainability of the expected investments has been prepared:

• The LIFE project will generate some revenues.
• The PBT of the plants will be around 4 years.
• It will produce an EBITDA of 15 Meur in the 5th year.

Consortium and Stakeholder Engagement

The Consortium is very solid, formed by experienced partners who cover the required value chain. INSPIREE will also consolidate the circular economy value chain related to REE-PM recycling thanks to crucial activities of stakeholder engagement.