Highlights

• Global rare earth magnet demand projected to exceed 200,000 tons by 2030, with severe environmental extraction impacts.
• China controls nearly 70% of rare earth production, creating significant geopolitical and supply chain risks.
• Researchers propose a three-part strategy:
  • Green mining
  • Circular economy recycling
  • Machine redesign to reduce rare earth dependency

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Lead authors Dr. Dan-Cristian Popa and Dr. Loránd Szabó, affiliated with the Electrical Machines and Drives Department, Technical University of Cluj-Napoca, Romania (opens in a new tab) explore a critical contradiction: rare earth permanent magnets are essential for green technologies such as electric vehicles (EVs) and wind turbines, yet the mining and processing of these materials is highly polluting, energy-intensive, and toxic. Their central hypothesis is that current rare earth usage in electrical machines represents an ecological Catch-22. The study seeks to map out sustainable pathways to reduce reliance on newly mined rare earths without derailing the green energy transition.

Study Method

This comprehensive literature review synthesizes dozens of peer-reviewed papers, international energy forecasts, industrial case studies, and regulatory frameworks. It investigates material efficiency innovations, sustainable supply chain strategies, and technical alternatives to rare earths in electrical machines.

Key Findings

The study finds that the global demand for rare earth magnets in green technologies—particularly in wind turbines and electric vehicles—is set to exceed 200,000 tons by 2030, with projected 16- to 30-fold increases in demand for neodymium, dysprosium, and terbium. However, the environmental cost of extracting these materials is severe, producing toxic dust, radioactive waste, and massive volumes of wastewater per ton mined. China currently controls nearly 70% of global rare earth production and continues to consolidate its dominance across the supply chain, posing major geopolitical risks. In response, the authors outline a three-part strategy: localizing supply chains through green mining, scaling circular economy models to recycle magnets, and redesigning machines to reduce or eliminate rare earth use altogether. Despite these efforts, recycling remains a major bottleneck, with only 1% of rare earths currently reclaimed and even best-case projections meeting just 10% of future demand.

Limitations

While the authors suggest promising R&D directions such as bioleaching and additive manufacturing, they acknowledge that most alternative technologies remain uneconomical or technologically immature. The review does not quantify the economic tradeoffs of transitioning away from rare earths in machine design or address the political feasibility of scaling Western supply chains.

Final Thoughts

Popa and Szabó’s work offers a rigorous and urgent assessment of the rare earth dilemma facing the global green transition. The study makes clear that technological substitution, policy incentives, and supply diversification must advance in lockstep. Without meaningful action, the world risks "solving" climate change while deepening environmental destruction and strategic dependency. Policymakers, industry stakeholders, and engineers must treat rare earth sustainability not as an afterthought, but as a first principle in the design of the clean energy economy.

Source: Renewable and Sustainable Energy Reviews, Volume 207, Article 114917 (opens in a new tab)