Design and optimization of processes for recovering rare earth elements from end‐of‐life permanent magnets

Laliwala, Chris; Amusat, Oluwamayowa O.; Ojo, Akintomiwa; Garciadiego, Alejandro; Tarka, Thomas; Bhattacharyya, Debangsu; Torres, Ana I.

doi:10.1002/aic.70208

Design and optimization of processes for recovering rare earth elements from end‐of‐life permanent magnets

Journal Article · Tue Feb 10 00:00:00 EST 2026 · AIChE Journal

DOI:https://doi.org/10.1002/aic.70208· OSTI ID:3019089

^[1]; Amusat, Oluwamayowa O. ^[2]; Ojo, Akintomiwa ^[3]; ^[4]; ^[4]; Bhattacharyya, Debangsu ^[3]; Torres, Ana I. ^[1]

Carnegie Mellon Univ., Pittsburgh, PA (United States)
Lawrence Berkeley National Laboratory (LBNL), Berkeley, CA (United States)
West Virginia Univ., Morgantown, WV (United States)
National Energy Technology Laboratory (NETL), Pittsburgh, PA (United States)

Recovery of rare earth elements (REEs) from end-of-life (EOL) products represents a strategic opportunity to strengthen the domestic supply chain for rare earth elements. This work presents a superstructure-based optimization framework for finding the most economical processing pathway for different EOL rare earth permanent magnets (REPMs). The framework evaluates state-of-the-art technologies across four processing stages—disassembly, demagnetization, leaching and extraction, and precipitation and calcination—using net present value (NPV) maximization and cost of recovery (COR) minimization objectives. A novel bottom-up costing framework for hydrogen decrepitation is also introduced. Two feedstocks were considered: REPMs from EOL hard disk drives (HDDs), and electric and hybrid electric vehicles (EVs and HEVs). While HDD recycling proved unprofitable due to limited feedstock availability, EVs/HEVs were profitable across a range of parameters and cost estimates. Therefore, our findings suggest that the proposed EOL EV/HEV recycling process may be economical and is worthy of further investigation.

View Accepted Manuscript (DOE)

Research Organization:: National Energy Technology Laboratory (NETL), Pittsburgh, PA, Morgantown, WV, and Albany, OR (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); USDOE Office of Fossil Energy and Carbon Management (FECM), Office of Resource Sustainability

Grant/Contract Number:: AC02-05CH11231; NA0003525

Other Award/Contract Number:: 89243323RCFE000075

OSTI ID:: 3019089

Journal Information:: AIChE Journal, Journal Name: AIChE Journal Journal Issue: 5 Vol. 72; ISSN 1547-5905; ISSN 0001-1541

Publisher:: American Institute of Chemical EngineersCopyright Statement

Country of Publication:: United States

Language:: English

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29 ENERGY PLANNING, POLICY, AND ECONOMY
36 MATERIALS SCIENCE
process optimization
rare earth elements
recycling
techno-economic analysis critical minerals

Design and optimization of processes for recovering rare earth elements from end‐of‐life permanent magnets

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