Highlights
- Researchers develop an innovative method to recover rare earth elements from discarded NdFeB magnets with 99.9% efficiency.
- New process uses carbon-based selective oxidation and supergravity separation at 1320°C, reducing energy consumption.
- Potential solution to reduce global dependence on Chinese rare earth processing.
- Implications for electric vehicle and renewable energy industries.
In a joint study (opens in a new tab) between the State Key Laboratory of Advanced Metallurgy (opens in a new tab), University of Science and Technology Beijing (opens in a new tab) and the University of Warwick (opens in a new tab), lead author Dr. Jintao Gao and colleagues have unveiled a promising new method to recover rare earth elements (REEs) from discarded NdFeB magnets—critical components in electric vehicles, wind turbines, and defense systems. Published in Separation and Purification Technology (Elsevier, October 2025), the team reports a 99.9% recovery rate of rare earths using an innovative process that merges selective oxidation with supergravity separation.
At a time when global reliance on China for rare earth element (REE) processing exceeds 85%, this low-temperature, high-efficiency technique could signal a new frontier in rare earth independence—if it can be commercialized.
The Potential Breakthrough
Researchers used carbon to selectively oxidize NdFeB magnet waste, transforming rare-earth metals into RE oxides while preserving iron in its metallic form. When combined with supergravity separation at just 1320°C, the method achieves:
- REE content of 82% in slag (vs. 67% from traditional methods)
- Iron separation efficiency with minimal contamination
- Nearly complete recovery of Nd and Pr with reduced energy demand
The key innovation lies in the use of supergravity fields—a centrifugal technique that intensifies phase separation without requiring full melting of all materials. Unlike conventional smelting, which is often performed at temperatures of≥1550°C, this method achieves cleaner separation at lower temperatures with reduced carbon and energy inputs.
Commercial Relevance and IP Gaps
The study is backed by China’s National Natural Science Foundation (opens in a new tab), but no patents or industrial licensing pathways have yet been announced. Despite the technique’s promise, commercial viability hinges on several unanswered questions:
- Scale-up Challenge: Supergravity separation has rarely been deployed at commercial metallurgical scales. Equipment retrofits could be cost-prohibitive.
- Feedstock Consistency: Real-world NdFeB waste varies in composition, coating, and degradation, complicating standardization.
- Product Use Readiness: The REEs-rich slag produced is high-grade, but its suitability for direct reuse in magnet manufacturing or oxide refining remains untested.
- Process Maturity: While lab-validated, the technique lacks pilot-scale demonstration—typically the bridge to investment and adoption.
Critical Assessment
This research represents a significant technical advancement, offering a more environmentally sustainable and efficient route for recycling rare earth magnets. If scaled, it could help reduce Western dependence on primary Chinese supply chains, particularly for neodymium and dysprosium.
However, without a clear path to IP protection, licensing, or industrial partnership, this remains a scientific advance rather than an industrial solution. Rare Earth Exchanges will closely monitor developments, particularly for any signs of technology transfer, Western adoption, or commercial pilots.
Citation:
Gao J. et al. (2025). A new method for efficient recovery of rare earth resources from NdFeB waste via selective oxidation and supergravity separation. Separation and Purification Technology, 370, 133219. https://doi.org/10.1016/j.seppur.2025.133219 (opens in a new tab)
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