Key Takeaways
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Researchers in Germany are testing two processes to recover valuable metals from old hard drives.
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Solid-state chlorination method uses ammonium chloride and heat to convert magnet metals into metal chlorides for recovery.
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Electrochemical processing process uses an electrolyte to extract boron before neodymium and iron are separated.
Discarded computer hard drives could become aes and other technologies. Researchers in Germany are testing two processes to recover valuable metals from old magnets, including a method that uses ammonium chloride instead of conventional hydrochloric acid
The work is part of the European Union-funded NEO-CYCLE project, in which researchers at the Fraunhofer Institute for Ceramic Technologies and Systems (IKTS) are working with TU Bergakademie Freiberg to recover neodymium, iron and boron from discarded hard disk drives (HDDs).
Neodymium-iron-boron magnets are among the strongest permanent magnets available. They are used in electric vehicle motors, wind turbines and electronic products such as speakers, smartphones and hard drives. However, recovering their constituent materials at the required purity for reuse is technically challenging.
Neodymium is particularly important because around 90 percent of the material is imported from China Much of Europe’s collected magnet waste is also sent to China for processing before the recovered materials are imported again
Recovering metals from old magnets
The NEO-CYCLE researchers are evaluating two approaches to separate valuable materials from magnets found in discarded computers and laptops.
The first is solid-state chlorination, which is being developed by project partner TU Bergakademie Freiberg. Instead of conventional hydrochloric acid, the process uses ammonium chloride added to a mixture containing neodymium, iron and boron recovered from magnet waste.
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When heated, the mixture is converted into metal chlorides and a high-purity ammonia solution. The approach builds on a patented process already used to recycle fluorescent lamps, which researchers are now testing for magnet recovery.
Initial results indicate that the method can separate metal chlorides from magnet material more efficiently, allowing nearly all the metals to be extracted while using comparatively small amounts of chemicals.
The second approach uses electrochemical processing. Researchers place powdered magnet waste in an electrochemical cell, where an electrolyte such as diluted sulfuric acid provides the medium for chemical reactions.
This process initially extracts boron into a solution, which can then be concentrated for use in the chemical and pharmaceutical industries.
Separating valuable materials for reuse
After the initial processing, researchers at Fraunhofer IKTS use hydrometallurgical techniques to separate the resulting materials. The team applies selective processing to recover neodymium and iron, allowing the metals to be obtained in pure salt forms.
The recovered materials can then undergo further processing by project partners for applications across several industries. These include chemicals, pharmaceuticals, hydrogen production, and fertilizers.
The researchers are also exploring ways to turn the recovered materials into higher-value products rather than simply extracting them from waste. This could help establish a circular supply chain in which discarded electronic components become feedstock for new industrial applications.
The four-year NEO-CYCLE project is funded through the European Union’s Horizon Europe program. Researchers have completed laboratory-scale testing of the recovery approaches, while plans for a pilot plant are underway.
The aim is to develop an economically and environmentally-of-life magnets while reducing chemical and water consumption. If successful, the approach could help Europe make better use of its electronic waste and reduce its dependence on imported critical raw materials
With over a decade-long career in journalism, Neetika Walter has worked with The Economic Times, ANI, and Hindustan Times, covering politics, business, technology, and the clean energy sector. Passionate about contemporary culture, books, poetry, and storytelling, she brings depth and insight to her writing. When she isn’t chasing stories, she’s likely lost in a book or enjoying the company of her dogs.
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