Potential for Nd and Dy Recovery from End-of-Life Products to Meet Future Electric Vehicle Demand in the U.S.

Abstract Rare earth elements (REEs) such as Neodymium (Nd) and Dysprosium (Dy) are used in Rare Earth Permanent Magnets (REPMs). Neodymium-iron-boron (NdFeB) magnets offer the strongest magnetic field per volume among all the magnets available in the market, which enables lightweight and compact product designs. NdFeB magnets have thus become indispensable in emerging clean technologies such as wind turbines and electric vehicles (EVs). Global demand for these renewables is increasing due to environmental considerations, energy security, and consumer demand. However, China’s dominance in REE production and processing technology has led to concerns pertaining to supply chain risks. This is especially the case for the automotive industry that is experiencing a major shift from traditional internal combustion engines to EVs that employ these REPMs. The number of EVs on U.S. roads is projected to reach more than 18 million in 2030 up from 1.4 million in 2019. In order to mitigate supply chain brittleness, and thereby potentially reduce price volatility, secondary REE supply sources from end-of-life (EoL) products may be a viable option. This study quantifies the recycling potential of Nd and Dy from EoL EVs, HDDs and MRIs in the U.S. Factors used in the analysis were number of units manufactured each year, NdFeB magnet mass in each unit and REE composition of magnets employed. Using EV production forecasts, we estimate how much of the future Nd and Dy demands can be met by secondary supply from EoL products.