SUSMAGPRO had ten specific objectives covering four areas:
Technical Objectives (TO), Economic Objectives (EO), Environmental Objectives (ENO) and Societal Objectives (SO).
The following work was carried out:
TO1: Automated pilot lines have been constructed to locate, identify and extract RE-magnets from waste. With a flexible design, the lines can handle different EoL parts such as loudspeakers, rotors, mixed waste electrical and electronic equipment (WEEE) or hard disk drives (HDD). The HDD line is designed in a modular and transportable manner, allowing on-site segregation of magnet-containing scrap and thus recovering the value of the magnets prior to secure data destruction, e.g. at computer server farms.
TO2: Three pilot plants in Germany, Slovenia and the UK have been developed and set up to recycle magnets in a shorter-loop using less chemicals with the patented Hydrogen-based Processing of Magnet Scrap (HPMS) technology. They have reached TRL 7–8, and are capable of processing 50 t/yr of clean RE powders; 10 t/yr for the pilot in Germany.
TO3: Four pilot remanufacturing processes have been developed, also in Germany, Slovenia and the UK, which convert extracted RE materials into either refined and purified cast alloys or magnets in sintered, injection-moulded or metal-injection-moulded forms. The remanufactured magnets have been tested in collaboration with industrial end-user companies to demonstrate that they meet industry standards.
TO4: 500 demonstrator components for rotors, sensors, pumps and loudspeaker modules based on recycled magnets have been produced to gain user acceptance for recycled products. More than 160 scrap sources have been analysed and integrated into a comprehensive database containing information on the chemical, geometric and magnetic properties of EoL magnets, the resulting HPMS powders and re-manufactured magnets. It will provide the basis for redesigning existing and new products to facilitate magnet recycling contribute to future standards for recycling-friendly designs.
EO1: A market analysis has been completed to determine the geographical locations, volumes, chemical compositions, and positions in applications for scrap RE magnets. Two tools have been developed: a material flow analysis model, that allows for a fine-grained analysis by providing information at the level of individual EU Member States and product groups; and a recyclability assessment framework, which provides insights into the broad set of factors that determine if recycling is successful.
EO2: Initial plans for the commercial exploitation of SUSMAGPRO industrial processes beyond the end of the project, in particular for spin-out companies called HyProMag, as well as further knowledge transfer and recommendations for policy and standardisation, have been drafted, accompanied by Techno-Economic Assessment. The target capability to sustainably produce 15% of EU demand (450 t/yr) for RE magnets within 5 years of the project was confirmed.
ENO1, 2 & 3 (to reduce the environmental impact and health risks associated with the presence of metals such as RE, to reduce the energy consumption, and the environmental damage associated with, the mining and refining of RE and to reduce the amount of waste related to applications entailing RE magnets by improving primary production recyclability) ran in parallel with Life Cycle and Social impact analyses. Comprehensive data has been generated and analysed and positive social and environmental effects, confirmed.
SO1 & 2: Various activities have been carried out to raise awareness of RE, its challenges and the solutions provided by the project. Findings have been communicated to the general public, research, industry, local and national governments and the European Commission through reports, trainings, press releases, social media, website, printed materials, scientific papers, participation in conferences and a public roadshow in several European cities. Clustering and synergy activities with related national and H2020 projects, ERMA, EIT RawMaterials, non-EU initiatives such as REIA and global standards organisations have been implemented.
