case study
Recycling of Rare Earth Elements From Neodymium Iron Boron (NdFeB) Magnets – Process Simulation and Technoeconomic Analysis
Project Summary
A government research agency engaged our team to perform a process simulation and technoeconomic analysis (TEA) of the magnet recycling flowsheet using hydrometallurgical processing and electrodialysis (ED)-based separation technology for recovering Neodymium (Nd) and Praseodymium (Pr). The project aimed to benchmark this method against traditional solvent extraction (SX) processes and support sustainable rare earth magnet manufacturing.
Challenge
Global demand for Nd and Pr continues to grow due to their critical role in permanent magnet production for electric vehicles, wind turbines, and electronics. However, traditional extraction processes are capital and energy intensive. The client sought to understand whether an ED-assisted separation process could provide a technically viable and economically competitive alternative to solvent extraction.
Solution
The engagement was divided into two key components:
1. Technoeconomic Analysis
Base Case:
- A rare earth oxide (REO) production facility in Ontario, serving U.S. markets.
ED vs. SX Comparison:
- Evaluated the feasibility of replacing SX stages with multi-stage ED units.
Economic Metrics Included:
- A capital (Class 5) and operating cost estimates
- Discounted cash flow (DCF) model
- Sensitivity to various parameters including, feedstock costs, REO pricing, and utility rates
Key Outputs:
- A capital (Class 5) and operating cost estimates
- Discounted cash flow (DCF) model
- Sensitivity to various parameters including, feedstock costs, REO pricing, and utility rates
2. Process Simulation of REE Recovery from End-of-Life NdFeB Magnets
Full Process Flowsheet Simulated:
- Leaching, neutralization, chelation (HEDTA), electrodialysis, crystallization, acid recovery, and electrowinning
Technical Highlights:
- Use of process simulators with advanced thermodynamic methods
- Simulation of over 15 interconnected unit operations
- Integration of closed-loop acid and reagent recovery
- HCl and HEDTA recycling modeled to reduce cost and environmental impact
- Process validated for potential scale-up
Key Results
Showcased the strong technical viability with moderate capital cost, lower chemical usage, and attractive recovery rates of ED-assisted process.
Process simulations confirmed the process could achieve high-purity Nd/Pr with integrated resource recycling.
TEA suggested competitive economics if integrated within a larger rare earth processing operation.
Environmental performance is enhanced through closed-loop acid and reagent recovery.
Business Impact
This project laid the foundation for:
- Investment decisions into pilot or demonstration-scale ED units
- Comparative positioning against or complementary to solvent extraction in technoeconomic and sustainability terms
- Future scale-up efforts for rare earth extraction from both mined ores and electronic waste (e-waste)
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