Sustainable Design for Recycling

REIA Webinar on Rare Earth Elements

in Sustainable Circular Economy

2020-10-01
Dr. Alexander Furgeri
Group Magnet & Magnetic-systems Expert
JLMAG Rare-Earth Co Europe B.V.
Outline

• Applications using NdFeB

• Recycling chain
• Sustainable Design for Recycling

2
Applications using NdFeB

3
Users of NdFeB

Automation

15% Wind Power

3C Electronics
31%

29%
25%

House Hold
Automotive

Source: Sales Field – 2018 Annual report JL MAG

4
 Distribution of NdFeB in future

Most industry applications have increasing demand of NdFeB but have almost stable shares
of the total NdFeB volume. The challenge of electrification for drivetrain will skip these shares
to majority of automotive business which is depending on highest performance magnets.

5
NdFeB flow
With the rapid growth of Automotive motor(EPS,pump,ebooster), Electric vehicle,
IT, wind power, household appliances applications, the usage of NdFeB magnet
has a big increase over the last 20 years. And the volume is still increasing rapidly.
Below shows China NdFeB output from 2015-2018. 65% is exported out of China
in the form of magnet or finished applications. Japan output is around 18000tons
per year mainly used for non China area. So magnet used outside China is 68.6%
of total global production.

6
RE market balance

For Nd and in particular for Dy a market deficit is predicted in the next years.
Recycling activities get more important when a deficit situation takes place.

7
Recycling chain

8
Sustainability and Recycling

Rare Increasing Energy and

Earth Chemical consumption
Ore
China prohibits
importation of
Application Rare Earth
used items
Carbonate

Importation of customer field reclaim to China is not

possible. Therefore recycling outside China gets
important.

NdFeB Rare
Earth
Oxide

Rare
Earth
Metal

9
 Recycling NdFeB
Rare Earth
Mine
Metals „Traditional way“: everything
back to the metal extraction
Casting

Strong acids
Melt
roasting Pulverizing
Chemical
Extraction Powder
Carbonate Pressing
Precipitation

Calcine to
Oxide
Sintering
Electrolysis Scrap
Machining
/GBD

China prohibits Slurry

Customer
importation of Field Reclaim
Coating
used items
10
 Recycling NdFeB
Mine Rare Earth
Metals Outside China the customer field reclaim can be
used for recycling.
Casting

Pulverizing

Pressing
Scrap

Sintering

Customer Machining Slurry

Field Reclaim /GBD

Coating

The later the re-use in the production chain the higher the sustainability 11
 Desing Impact for Sustainable Recycling

Customer Non- Magnet Same or

Application Magnet
Field Destructive Remanu- new
Disassembly cleaning
Reclaim Disassembly facturing Application

Blending
with new Pulverizing
powder
Pressing

Destructive Sintering
Pulverizing
Disassembly
Machining
Pressing /GBD
Blending
with new Coating
Sintering
powder
Problem: Machining
/GBD
Destructive disassembly provokes
impurities disturbing the magnet Coating
production process.
12
 Desing Impact for Sustainable Recycling

Crushing of • Foreign materials have big fraction

application sub
assemblies • Cleaning of magnet powder impossible
e.g. rotors • Only Metal extraction feasible

Crushing of • Foreign materials have low fraction

magnets
e.g. Hydrogen
• Cleaning of magnet powder impossible
decripitation • Either Metal extraction or powderization feasible

• Foreign materials have low fraction

Mechanical
removal with • Cleaning of magnet get possible
broken • Powderization feasible
magnets
• Remanufacturing feasible

The easy removal of magnets as total piece is essential for a sustainable recycling!

13
 Complexity of material choice
N58
N56 56M 56H 56SH Supplier table after RE crisis
N54 54M 54H 54SH 54UH
Dy free grade
[MGsOe]
BH max

N52 52M 52H 52SH 52UH

50EH Oxygen controlled process
N50 50M 50H 50SH 50UH
N48 48M 48H 48SH 48UH 48EH
GBD process
N45 45M 45H 45SH 45UH 45EH 45AH
GBD +fine grain technology
N42 42M 42H 42SH 42UH 42EH 42AH
N40 40M 40H 40SH 40UH 40EH 40AH 40VH
N38 38M 38H 38SH 38UH 38EH 38AH 38VH
N35 35M 35H 35SH 35UH 35EH 35AH 35VH
33H 33SH 33UH 33EH 33AH 33VH
30SH 30UH 30EH 30AH 30VH
28UH 28EH 28AH 28VH
11 12 14 17 20 25 30 35 40 Hcj [kOe]

80 100 120 150 180 200 230 260 Tworking [°C]

Users of NdFeB realized that the use of HRE is essential to know.

Depending on user‘s own strategy the table looks different to him.
14
 NdFeB grades used by applications

Automation N
5
5
2
5
2
5
2
5
2

[MGsOe]
S U

BH max
2 M H H5 5H
N 5 5 0 0
5 0 0 S U
0 M H 4H 4 4
N 4 4 H 8
8 8
4 8 8 E

Wind Power
S U
8 M H 4 4 4H 4
N 4 4 H H
5 5 5 5
4 5 5 A
S U E
5 M H 4 4 4 4
H
N 4 4 H H H
2 2 2 2
4 2 2
S U E A
2 M H 4 4 4 4 4 N
N 4 4 H H H H 5
0 0 0 0 0 8
4 0 0
S U E A V 5
0 M H 3 3 3 3 3 N 5 5 6
N 3 3 H H H H H 5 6 6 S
8 8 8 8 8 6 M H H
3 8 8 5
5
S U E A V N 5 5 4
4
8 M H 3 3 3 3 3 5 4 4 S
U
N 3 3 H H H H H 4 M H H
H
5 5 5 5 5 5 5
3 5 5 N 5 5

BH max [MGsOe]
2 2
S U E A V 5 2 2 S U
5 M H 3 3 3 3 3 2 M H H H
3 H H H H H 5
5
3 3 3 3 3 N 5 5 0
5 0
3 5 0 0 S
0 E
S U E A V 0 M H H
U H
H 3 3 3 3 3 H
H H H H H N 4 4 4 4 4
8
0 0 0 0 0 4 8 8 8
S
8
U E
8 M H H
S U E A V H H
2 2 2 2 N 4 4 4 4 4 4
H H H H H 4 5 5 5 5 5 5
8 8 8 8 5 M H S
H
U
H
E
H
A
H
U E A V N 4 4
4 4 4 4
2 2 2 2
H H H H 4
2
2
M
2
H
S U E A
H H H H
4 4 4 4 4
N 4 4
0 0 0 0 0
4 0 0
S U E A V
0 M H
H H H H H
3 3 3 3 3
N 3 3
8 8 8 8 8
3 8 8
S U E A V
8 M H
H H H H H
3 3 3 3 3

3C Electronics
N 3 3
5 5 5 5 5
3 5 5
S U E A V
5 M H
H H H H H
3 3 3 3 3
3
3 3 3 3 3
3
S U E A V
H
H H H H H
3 3 3 3 3
0 0 0 0 0
S U E A V
H H H H H
2 2 2 2
8 8 8 8
U E A V
H H H H

1 1 1 1 2 2 3 3 4 Hcj [kOe]
1 2 4 7 0 5 0 5 0

N58
80 100 120 150 180 200 230 26
0

N56 56M 56H 56SH

54UH
N54 54M 54SH
54H

N52 52M 52H 52SH 52UH

50EH
N50 50M 50H 50SH 50UH

N48 48M 48UH 48EH

48H 48SH

N45 45M 45H 45SH 45UH 45EH 45AH

5 5
N 5 5 2
N42 42M 42H 42SH 42UH 42EH 42AH 2
5 2 2

[MGsOe]
S U

BH max
2 5 5
N 5M H
5 H H
0 0
N40 40M 40H 40SH 40UH 40EH 40AH 40VH 5 0 0 S U 4
0 M H 4 4
N 4 4 H H 8
8 8
4 8 8 E
N38 38M 38H 38SH 38UH 38EH 38AH 38VH
U
8 M H 4S 4 4
H
4
N 4 4 H
5H 5 5 5
4 5 5 A
N35 35M 35H 35SH 35UH 35EH 35AH 35VH S4 U
4 E4 4
5
N M
4 H
4 H
H2 H
2 H2 2
4 2 2
4S 4U 4E 4A 4
N2 4M 4H
33H 33SH 33UH 33EH 33AH 33VH

0H 0H 0H 0H 0
4 0 0
S3 U
3 E3 A
3 3V
30SH 30EH 30AH 30VH 0
N M
3 H
3
30UH
H8 H
8 H8 H
8 8H
3 8 8
S3 U
3 E3 A
3 V
3
8
N M
3 H
3
28UH 28EH 28AH 28VH H 5 H
5 H 5 H
5 H
5
3 5 5
S3 U3 E3 A3 V3
5 M H3
H3 H3 H3 H3 H3
1 1 1 1 2 2 3 3 4 Hcj [kOe]
3
1 2 4 7 0 5 0 5 0
S U E A V
H 3 3 3 3 3
H H H H H
0 0 0 0 0
S 2U E2 A
2 V
2
H 8H H8 H
8 H
8
U E A V
H H H H
N58

Hcj [kOe]
N56 56M 56H 56SH

HEV/EV
54UH
N54 54M 54H 54SH
BH max [MGsOe]

N52 52M 52H 52SH 52UH

50EH
N50 50M 50H 50SH 50UH

N48 48M 48UH 48EH

48H 48SH

N45 45M 45H 45SH 45UH 45EH 45AH

N42 42M 42H 42SH 42UH 42EH 42AH

N40 40M 40H 40SH 40UH 40EH 40AH 40VH

N38 38M 38H 38SH 38UH 38EH 38AH 38VH

N35 35M 35H 35SH 35UH 35EH 35AH 35VH

33H 33SH 33UH 33EH 33AH 33VH

House Hold
30SH 30UH 30EH 30AH 30VH

28UH 28EH 28AH 28VH

Other Automotive

The shares of applications use similiar material grades. But not same ones… 15
Design of NdFeB magnets for E-Power

Wind Power Water Power

E-Power generation

E-Power magnets usually have big dimensions

and have HRE-free and highest Br NdFeB
in focus.

Tidal Power
Images provided by courtesy of Open hydro 16
Design of NdFeB magnets for E-Power

N58
N56 56M 56H 56SH
N54 54M 54H 54SH
54UH

N52 52M 52H 52SH 52UH

N50 50M 50H

BH max [MGsOe]
50EH
50SH 50UH

N48 48M 48H 48SH

48UH
48EH

N45 45M 45H 45UH 45EH 45AH

45SH

N42 42M 42H 42UH 42EH 42AH

42SH

N40 40M 40H 40UH 40EH 40AH 40VH

40SH

N38 38M 38H 38UH 38EH 38AH 38VH

38SH

N35 35M 35H 35UH 35EH 35AH 35VH

35SH

33H 33UH 33EH 33AH 33VH

33SH

30UH 30EH 30AH 30VH

30SH

28UH 28EH 28AH 28VH

11 12 14 17 20 25 30 35 40 Hcj [kOe]

80 100 120 150 180 200 230 260

• Reverse logistics easy possible because of non moving applications

• Easy material grade collection
• Highest Remanence and/or HRE-free in focus
• High requirements coating (NiCuNi, SSR, Epoxy, Combinations)
• Big amount of NdFeB profitable for non destructive-removal
• Big size of magnets suitable for coating removal and cutting
• Grades are suitable for blending with new powder and for Grain Boundary Diffusion
E-Power has advantageous situation for recycling.
17
Design of NdFeB magnets for 3C Electronics

N58

N56 56M
56H 56SH
N54 54M
54H 54SH 54UH
N52 52M 52H 52SH 52UH
50EH
N50 50M 50H 50SH
50UH
N48 48M 48H 48UH 48EH
48SH

N45 45M 45H 45SH 45UH 45EH 45AH

N42 42M 42H 42SH 42UH 42EH 42AH

N40 40M 40H 40SH 40UH 40EH 40AH 40VH

N38 38M 38H 38SH 38UH 38EH 38AH 38VH

N35 35M 35H 35SH 35UH 35EH 35AH 35VH

33H 33SH 33UH 33EH 33AH 33VH

3C Electronics 30SH 30UH

28UH
30EH

28EH
30AH

28AH
30VH

28VH

11 12 14 17 20 25 30 35 40 Hcj [kOe]

• Reverse logistics difficult because of world wide distribution

• Reverse logistics difficult because of spread of grades
• Focusing on highest Br with average HcJ
• Magnet dimensions very small
• Magnet dimensions very functional instead cost-wise/production- wise optimized
• Re-manufacturing difficult
• High Integration level provokes destructive disassembly
3C Electronics has disadvantageous basis for recycling.
18
Design of NdFeB magnets for House Hold
N58

N56 56M
56H 56SH
N54 54M
54H 54SH 54UH
N52 52M 52H 52SH 52UH
50EH
N50 50M 50H 50SH
50UH
N48 48M 48H 48UH 48EH
48SH

N45 45M 45H 45SH 45UH 45EH 45AH

N42 42M 42H 42SH 42UH 42EH 42AH

N40 40M 40H 40SH 40UH 40EH 40AH 40VH

N38 38M 38H 38SH 38UH 38EH 38AH 38VH

N35 35M 35H 35SH 35UH 35EH 35AH 35VH

33H 33SH 33UH 33EH 33AH 33VH

30SH 30UH 30EH 30AH 30VH

28UH 28EH 28AH 28VH

11 12 14 17 20 25 30 35 40 Hcj [kOe]

• Reverse logistics difficult because of world wide distribution

• Reverse logistics difficult because of spread of grades
• Focussing on highest Br with average HcJ
• Magnet dimensions on average level and profitability for collection depending
on RE-price level
• Non-destructive disassembly possible
• Dimensions suitable for re-manufacturing
House Hold has advantageous basis for recycling.
19
Design of NdFeB magnets for Automation

[MGsOe]
N52 52M 52H 52SH 52UH

BH max
N50 50M 50H 50SH 50UH

N48 48M 48H 48UH 48EH

48SH

N45 45M 45H 45SH 45UH 45EH 45AH

N42 42M 42H 42SH 42UH 42EH 42AH

N40 40M 40H 40SH 40UH 40EH 40AH 40VH

N38 38M 38H 38SH 38UH 38EH 38AH 38VH

N35 35M 35H 35SH 35UH 35EH 35AH 35VH

33H 33SH 33UH 33EH 33AH 33VH

30SH 30UH 30EH 30AH 30VH

28UH 28EH 28AH 28VH

HcJ

• Reverse logistics difficult because of world wide distribution

• Reverse logistics difficult because of spread of grades
• Focussing on moderate Br with average HcJ
• Magnet dimensions on average level and profitability for collection depending
on RE-price level
• Non-destructive disassembly possible
• Dimensions suitable for re-manufacturing
• Low Br requires a lot of new high-Br powder for blending

Automation has moderate basis for recycling.

20
Design of NdFeB magnets for Automotive

N58

N56

56M 56H 56SH

N54

54M 54H 54SH 54UH

[MGsOe]
N52

52M 52H 52SH 52UH

BH max
N50

50M 50H 50SH 50UH

50EH

N48

48M 48H 48SH 48UH

48EH

N45 45M 45H 45SH 45UH 45EH 45AH

42SH
Other Automotive
N42 42M 42H 42UH 42EH 42AH

N40 40M 40H 40SH 40EH 40AH 40VH

40UH

N38 38M 38H

38SH 38UH 38EH 38AH 38VH

N35 35M 35H

35SH 35UH 35EH 35AH 35VH

33H 33SH 33EH 33AH 33VH

33UH

30SH 30EH 30AH 30VH

30UH

28UH 28EH 28AH 28VH

HcJ

• Reverse logistics difficult because of world wide distribution

• Reverse logistics difficult because of spread of grades
• Focussing on high Br with low-average HcJ
• Magnet dimensions on lower level and profitability for collection depending on
RE-price level
• Non-destructive disassembly depending on magnet fixation concepts
• Dimensions not always suitable for re-manufacturing

Automotive (non Drivetrain) has moderate basis for recycling.

21
Design of NdFeB magnets for Drivetrain

EV

E-Train

Electrification products get the applications with

biggest market share in future

22
Design of NdFeB magnets for Drivetrain
N52

52SH
N52 52M 52H

N52 52M 52H

52SH

54UH

[MGsOe]
52UH

BH max
52SH
N52 52M 52H

N50 50M 50H

50SH

50UH
N48 48M 48H
48SH
48UH 48EH
N45 45M 45H 45SH

45UH 45EH 45AH

N42 42M 42H 42SH 42UH

42EH 42AH
N40 40M 40H 40SH 40UH 40EH

40AH 40VH
N38 38M 38H 38SH 38UH 38EH 38AH

38VH
N35 35M 35H 35SH 35UH 35EH 35AH

35VH
33H 33SH 33UH 33EH 33AH

33VH
30SH 30UH 30EH 30AH 30VH

28UH 28EH 28AH 28VH

Hcj [kOe]

• Reverse logistics difficult because of world wide distribution

• Reverse logistics difficult because of spread of grades
• Focussing on high Br with high HcJ
• Either passivation or Epoxy coating
• Magnet dimensions on lower to moderate level for re-manufacturing
• profitable for collection because of high magnet content within application (1-2.5kg)
• Non-destructive disassembly depending on magnet fixation concepts

Drivetrain has moderate to good basis for recycling. 23

Sustainable Design for Recycling

24
Design Impact for Recycling

Economical impact

• Compromise between high integration level and „fast path“

Disassembly Cost reduction to the magnets
• No use of sticky materials, e.g. glue, molding, etc…
• Use of removable fixation as like clamps, springs, etc….

• Non destructive disassembly

Re-use / Re-manufacturing • New projects with same/smaller magnet geometry
enableing • New projects with same/or similar grade
• Corrosion protection

Recycling Cost • Big recycling batch sizes

• Higher grades for less additional blending
reduction • Low Impurities for less additional blending

25
Design Impact for Recycling

Technical impact

• Same or similiar grades in one recycling batch

• Material label
• No impurities of foreign materials
Powderization enabling
Critical: In particular carbon reduces HcJ
→ No Glue or Overmolding
→ No Epoxy or SSR coating

• Plattform designs with same/similiar magnet grades and geometries

Re-use / Re-manufacturing • Easy geometry, e.g. blocks
• Material label
enabling • Avoid Corrosion by shielding magnet component instead of coating
• Low HcJ to be preferred due to re-magnetization

26
Thank you for listening!

Are there any questions ?

27