NdFeB permanent magnets have different life cycles, depending on the applications: from as short as 2–3 years in consumer electronics to 20–30 years in wind turbines. The size of the magnets ranges from less than 1 g in small consumer electronics to about 1 kg in electric vehicles (EVs) and hybrid and electric vehicles (HEVs), and can be as large as 1000–2000 kg in the generators of modern wind turbines. NdFeB permanent magnets contain about 31–32 wt% of rare-earth elements (REEs). Recycling of REEs contained in this type of magnets from the End-of-Life (EOL) products will play an important and complementary role in the total supply of REEs in the future. However, collection and recovery of the magnets from small consumer electronics imposes great social and technological challenges. This paper gives an overview of the sources of NdFeB permanent magnets related to their applications, followed by a summary of the various available technologies to recover the REEs from these magnets, including physical processing and separation, direct alloy production, and metallurgical extraction and recovery. At present, no commercial operation has been identified for recycling the EOL NdFeB permanent magnets and the recovery of the associated REE content. Most of the processing methods are still at various research and development stages. It is estimated that in the coming 10–15 years, the recycled REEs from EOL permanent magnets will play a significant role in the total REE supply in the magnet sector, provided that efficient technologies will be developed and implemented in practice.

This position paper introduces the reader to the concept of solvometallurgy, the term used to describe the extraction of metals from ores, industrial process residues, production scrap, and urban waste using non-aqueous solutions. Here, non-aqueous is not used to imply anhydrous, but rather a low water content. The unit operations are as follows: solvent leaching; separation of the residue; purification of the leach solution by non-aqueous solvent extraction or non-aqueous ion exchange; and metal recovery by precipitation or electrolysis in non-aqueous electrolytes. Solvometallurgy is similar to hydrometallurgy in that both the branches of extractive metallurgy use low-temperature processes, but with solvometallurgy, there is no discrete water phase. Both branches use organic or inorganic solvents (excluding water in the case of solvometallurgy). However, for solvometallurgical processes to be sustainable, they must be based on green solvents, which means that all toxic or environmentally harmful solvents must be avoided. Solvometallurgy is complementary to pyrometallurgy and hydrometallurgy, but this new approach offers several advantages. First, the consumption of water is very limited, and so the generation of wastewater can be avoided. Second, the leaching and solvent extraction can be combined to form a single step, resulting in more simplified process flow sheets. Third, solvent leaching is often more selective than leaching with acidic aqueous solutions, leading to reduced acid consumption and fewer purification steps. Fourth, solvometallurgy is useful for the treatment of ores rich in soluble silica (e.g., eudialyte) because no silica gel is formed. In short, solvometallurgy is in a position to help develop the near-zero-waste metallurgical processes, and with levels of energy consumption that are much lower than those with the high-temperature processes. The Technology Readiness Level (TRL) of this emerging branch of extractive metallurgy is still low (TRL = 3–4), which is a disadvantage for short-term implementation, but offers a great opportunity for further research, development, and innovation.

The balance between the market demand and the natural abundance of the rare-earth elements (REEs) in ores, often referred to as the Balance Problem (or the Balancing Problem), is a major issue for REE suppliers. The ideal situation is a perfect match between the market demand for and the production of REEs, so that there are no surpluses of any of the REEs. This means that the rare-earth industry must find new uses for REEs that are available in excess and search for substitutes for REEs that have either limited availability or are high in demand. We present an overview of the trends in the applications for the different REEs and show that the demand for REEs for use in magnets, catalysts, and alloys is still increasing, while the application of REEs in polishing agents, glass, and ceramics are stable. On the other hand, the use of REEs in nickel–metal-hydride (NiMH) batteries and lamp phosphors is decreasing. These changes in the REE market have an influence on the Balance Problem, because the REEs that can be recycled from fluorescent lamps, cathode-ray tubes (CRTs), and NiMH batteries have to be at least partly reused in other applications. Magnesium and aluminum alloys offer an opportunity to mitigate the Balance Problem caused by these changes in the REE market. This is illustrated for REEs that can be recycled from fluorescent-lamp phosphor waste, CRT phosphors, and NiMH batteries. At present, five REEs (Nd, Eu, Tb, Dy, and Y) are being considered as very critical by Europe, the United States, and Japan, but we forecast that in the medium term, only neodymium will remain a critical REE. This paper discusses the relationship between criticality and the Balance Problem and shows how this relationship influences the market for specific REEs.