Rare earth magnets are everywhere: powering the motors in electric vehicles, driving speakers in smartphones and high-end earbuds, generating electricity in wind turbines, and even generating lifesaving medical visualizations from magnetic resonance imaging (MRI). But what happens when these devices reach the end of their lives? Most of the time, nothing. Despite their technological importance, less than 1% of rare earth magnets are currently recycled. Not only is it a missed opportunity, it’s also a growing vulnerability for supply chains worldwide.
This blog marks the final installment of our From Rock to Rare blog series, where we’ve followed the rare earth element journey from the mine to magnets for advanced applications. In this closing chapter, we shift our focus to what happens after products reach the end of their use-cycle. Innovative recycling strategies could transform rare earth magnets from a disposal challenge into an essential resource for consumer goods, energy independence, and national security applications.
Recycling those small (but powerful) magnet components isn’t easy. Although many consumer electronics may last just two or three years, the rare earth magnets inside them are built to last decades. Unfortunately, after that smartphone or set of earbuds is discarded, it’s often mixed with other e-waste and then shredded. Once this happens, the magnets break into powder, cling to any ferromagnetic material, and become nearly impossible to separate. New chemical processes are emerging to tackle the challenge of rare earth magnet recycling, focusing on more efficient, sustainable, and scalable ways to recover valuable materials.
Two efficient methods are gaining momentum in rare earth magnet recycling: closed loop hydrometallurgy and hydrogen processing of magnet scrap (HPMS). Each has its own strengths and challenges, but both show promise in creating a more sustainable rare earth ecosystem.
1. Closed Loop Hydrometallurgy (i.e., with acid recycling) – this approach involves dissolving REE magnet waste in acid to extract the valuable elements:
a. Acid Leaching – dissolves REEs like Nd, Pr, and Dy into a liquid solution.
b. Selective Precipitation – oxalic acid is used to pull REEs out of the solution, separating them from unwanted elements.
c. Acid Regeneration – the hydrochloric acid used in leaching is regenerated during precipitation and reused, cutting down on waste and cost.
d. Reuse – the recovered REEs are turned into oxide feedstock for new magnet manufacturing, while iron-rich byproducts can be reused elsewhere.
2. Hydrogen Processing of Magnet Scrap (HPMS) – this approach exploits the phenomenon of hydrogen embrittlement, more typically considered a problem by metallurgists, to efficiently breakdown end-of-life REE magnets:
a. Hydrogen Exposure – end-of-life magnets are exposed to hydrogen gas, which embrittles and demagnetizes them. This causes the magnet to crumble into powder without the need for shredding.
b. Separation – nickel coatings peel off and can be mechanically removed. The resulting powder is a pure NdFeB alloy.
c. Reprocessing – the powder is re-sintered or melted into new magnets, suitable for myriad uses.
Pyrometallurgy, the high-heat method traditionally used to recover metals, is often dismissed due to its energy use and emissions. But new innovations like selective chlorination (which forms volatile REE chlorides at lower temperatures) are making it more competitive with closed loop hydrometallurgy and HPMS from an efficiency standpoint.
Through smart chemistry and design, the rare earth magnet recycling landscape is shifting. As we move toward a future of cleaner technologies and circular economies, finding ways to recapture these essential materials from our trash might be just as important as extracting them from the earth.
Importantly, efficient recycling helps safeguard national security by turning materials we already have on hand into a reliable and readily exploitable resource. This reduces our dependence on imports and the associated supply chain hazards while simultaneously supporting domestic production of REE magnets.
At EAG Laboratories, we specialize in providing the analytical expertise needed to ensure that rare earth materials meet your specifications at any stage of the lifecycle. From elemental compositional analysis of ore concentrates to impurity detection in recycled products, our state-of-the-art testing helps manufacturers achieve the perfect balance of performance and durability. EAG Laboratories can be your trusted partner for precise, reliable results every time. Contact an expert today.
As we close the From Rock to Rare series, one thing is clear: the rare earth supply chain is as much about innovation and collaboration as it is about extraction and processing. From mining to the final product, every stage requires expertise, precision, and trust.
At EAG Laboratories, we’re proud to be a part of that journey, helping turn raw potential into rare performance.
Automated Test Equipment (ATE) systems are carefully designed to test a wide range of semiconductor devices. EAG provides tailored ATE test solutions to meet the unique needs of clients.
Electrical AFM can measure the electrical/electromechanical properties of various functional materials and samples. This helps distinguish between conductive and nonconductive areas or polar and nonpolar regions of a device.
During this live Ask the Expert event, we will answer pre-submitted questions from our audience regarding characterization of polymeric materials used for product development, R&D, and failure analysis.
A device manufacturer observed defects in a lot of thermoplastic tubing. The tubing exhibited signs chemical attack or exposure to heating.
To enable certain features and improve your experience with us, this site stores cookies on your computer. Please click Continue to provide your authorization and permanently remove this message.
To find out more, please see our privacy policy.