Life cycle inventory database of Nd–Fe–B permanent magnet recycling for the evaluation from lab to fab

Abstract

Neodymium-iron-Boron permanent magnets are crucial components for a broad range of high-end technological applications, from renewable energy generators and electric vehicles to consumer electronics. This drives growing demand for rare earth elements, intensifying the challenges linked to resource scarcity and environmental impacts. This thesis compiles a life cycle inventory (LCI) database that maps the recycling pathways of NdFeB permanent magnets from laboratory settings to full-scale industrial applications. A series of Material Flow Analyses and prospective Life Cycle Assessments are employed to evaluate multiple recycling routes, including hydrogen decrepitation, metallurgical methods (hydrometallurgical and pyrometallurgical), as well as magnet‐to‐magnet processes. By analyzing and assessing the various impacts of these recycling scenarios against conventional primary production, the study quantifies the potential reductions in energy consumption, greenhouse gas emissions, and dependency on virgin rare-earth mining. The findings reveal that increased circularity in processing end-of-life magnets can substantially reduce environmental burdens and resource depletion, signifying there is considerable economic and ecological viability of recycled materials. This work not only provides a robust evaluative framework for assessing recycling technologies at different Technology Readiness Levels but also offers strategic insights for optimizing recycling efficiencies and supporting the broader transition toward a sustainable, circular economy for rare earth elements.