REEPRODUCE · Dismantling and recycling Rare Earth Elements from End-of-life products for the European Green Transition

Europe's ambitious energy and climate goals are heavily dependent on critical raw materials such as Rare Earth Elements (REEs). The largest end-user of REEs is the permanent magnet (PM) industry for electric mobility and renewable energy technologies. The growth in those strategic sectors till 2050 is expected to increase the demand of Neodymium (Nd) and Dysprosium (Dy) by ~4 and ~12 times, respectively. However, Europe depends 100% on REEs imports and there are no market-ready substitutes. Despite the fact that significant amounts of EoL products containing REE-based PMs are collected in Europe, the current recycling processes do not allow PMs recovery, and therefore they are lost downstream. To face this challenge, the REEPRODUCE project aims at setting up, for the first time, a resilient and complete European REEs-recycling value chain, at industrial scale for the recovery of REEs at competitive cost compared to REEs primary production in China (at least 25% cheaper) with environmentally friendly and socially sustainable technologies. REEPRODUCE will capitalize on the knowledge generated in previous projects and aim to solve all remaining technical challenges along the value chain to construct pilots able to produce 70 t of PMs per year from variety of EoL products bearing Nd-based PMs. Additionally it will demonstrate the conversion of PMs extracted from many different EoL products into high purity Rare Earth Elements Oxide (REO)-mixtures and Rare Earth Elements Alloy (REA) that will be used in the manufacturing of new PMs with performances similar to those manufactured with virgin REEs-intensive materials. This project is formed by key partners covering the whole value chain, including EoL products recyclers, metal recyclers, manufacturers of equipment for recycling, producers of REEs-intensive material and PMs, developers of technologies successfully proven in previous projects, and experts in dissemination, communication and exploitation.