Exploring mass and economic potentials of rare earth elements recycling from electric vehicles at end-of-life

Abstract Rare earth elements (REEs) are fundamental for various modern technologies and industrial applications. One significant application of REEs is in the production of neodymium-iron-boron (NdFeB) magnets, which are key components in electric vehicles (EVs), wind turbines, and electronic devices. These applications play a crucial role in driving the ecological and digital transition, highlighting the significance of REEs as strategic materials. With the dominance of very few countries in the REEs global supply and the rising of EVs demand, several concerns regarding resource availability, supply chain security, and price volatility have heightened the importance of efficient NdFeB magnet recycling, especially in Europe. This study assessed the elemental recycling potential of REEs from EV components through collaboration with authorized treatment facilities and metal recyclers in Italy. The study focused on three representative electric vehicles: a compact car, a van, and a hybrid vehicle. NdFeB magnets were found in various components, including the electric drive motor, air conditioning system, electric power steering, alternator, and electric gear box. The content of NdFeB magnets and REEs inside these components has been determined and economic feasibility of their recycling has been estimated by considering the intrinsic value of the raw materials contained. Despite being preliminary results, the economic value of REEs and Cu recoverable attested a promising potential for recycling, while the direct dismantling of magnets from the engine proves economically unviable for the studied components. Therefore, the study emphasizes the need for the development of specific recycling processes such as demagnetization and mechanical processing of the motors. The study also analysed the dismantling times of the target components from the vehicle and their relative economic impact on the potential for recovery.