a. What is the problem/issue being addressed?
As increasing numbers of vehicles on our roads become powered by electricity, the problem of how to effectively recycle the rare-earth magnets contained in the motors and generators of these hybrid and full-electric vehicles (EVs) intensifies. In response to this the DEMETER project – the European Training Network for the Design and Recycling of Rare-Earth Permanent Magnet Motors and Generators in Hybrid and Full Electric Vehicles – has looked to solve many of the scientific and technical problems that are currently preventing the effective recycling of these critical materials.
Firstly, the magnets must be identified and removed from existing devices. Then they need to be reprocessed, with the properties of the new magnets being good enough for them to be incorporated into new motors, which of course must be designed in such a way that at their end-of-life (EoL) they can be more easily recycled.
b. Why is it important for society?
Rare earths are vital because they have unique properties, which means that in many cases they cannot be substituted with another element without greatly reducing performance. And this is not just for permanent magnets – although this is probably the largest single use at the moment – but for the many other industries that rely on them. We find rare earths in camera and telescope lenses, catalytic converters, aircraft engines, visors to protect welders and glassmakers, X-ray and MRI scanning systems, televisions and computer screens and other devices that have visual displays. If the supply of rare earths was restricted or even halted, then European society would be very severely affected, probably within weeks. Many industries would be severely hit, jobs would be lost, and manufacturers of products reliant on rare earths would have to stop production. Being able to guarantee the supply of rare earths through a large-scale programme of recycling is Europe’s only option.
c. What are the overall objectives?
The DEMETER project focused on the extraction and recycling of the relatively large rare-earth permanent magnets in electrical drives. In addition to this, DEMETER developed recycling for Nd-Fe-B and Sm-Co magnets, and designed electric motors for the next generation of electric vehicles. Finally, the project developed a complete, “urban-mine to machine”, lifecycle assessment and lifecycle costing methodology for rare-earth permanent magnets to ensure the most environmentally friendly and economical routes are applied for recycling.
d. The conclusions of the action
The 15 ESRs in the project, individually took on huge challenges. They moved to a new country, began work on a new research project, and the majority of them flourished and are now establishing themselves as self-assured, independently minded researchers who are looking forward to interesting careers. They have received top-class training which means they are ready to tackle future challenges with confidence and make a contribution to society.
Their individual research projects have generated some remarkable results. There have been a number of publications in high-impact journals and some very important conference presentations. The ideas relating to the recycling of rare-earth magnets have been advanced on many fronts, and we can conclude that DEMETER has done much to further European aims for a healthier, greener and more sustainable economy.
