The RESOLVE project, in collaboration with Aalen University, has developed a new separation process to improve the efficiency of rare earth magnet recycling. The University of Pforzheim is working on converting magnet scrap into high quality recycling powder, which Aalen University is processing into sintered magnets using new additive systems. This addresses the EU's critical rare earth supply risk.

Recycling neodymium-iron-boron magnets is a partial solution to the EU's rare earth supply. Pyro- and hydrometallurgical recycling as well as Hydrogen Processing of Magnetic Scrap (HPMS) are viable methods. However, due to the reactivity of RE elements, recycled magnets contain a neodymium-rich phase with higher oxygen content, which affects magnet quality. This study investigates a combined HPMS and leaching process to separate this phase from the hard magnetic phase. End-of-life wind power magnets treated with organic acid as a leaching agent were used. Optimal conditions for effective separation were found and the influence of each step on oxygen content is evaluated.