German Researchers Recover 85% of Rare Earths from Discarded Magnets in Recycling Breakthrough

Highlights

• TU Clausthal and TU Bergakademie Freiberg researchers achieved ~85% overall rare earth recovery from end-of-life NdFeB magnets using slag extraction and hydrometallurgy.
• The process uses 1,700°C smelting followed by hydrochloric acid leaching and oxalic acid precipitation, scaling from 50g to 1.35kg in lab tests.
• Researchers produced a mixed rare earth compound, not separated magnet-grade metals, meaning further refining steps are needed before commercial magnet production.
• Oxalic acid consumption ran five times the theoretical requirement, and energy costs at 1,700°C remain a key barrier to commercial viability.
• The study highlights recycling as a potential pillar of European rare earth security, but only if paired with domestic refining and magnet manufacturing capacity.