Researchers at Kyoto University’s Institute for Integrated Cell‑Material Sciences (iCeMS) have developed a new process for recycling rare‑earth metals from discarded magnets using only molten salts. Their selective extraction‑evaporation‑electrolysis (SEEE) technique, described in August 2025, provides an environmentally friendly alternative to existing hydrometallurgical and pyrometallurgical recycling methods. By recovering critical elements like neodymium and dysprosium, the method aims to secure supplies for electric vehicle motors and wind turbine generators without the environmental damage of mining.
According to the study, magnet scraps are immersed in a molten mixture of calcium chloride and magnesium chloride with a small amount of calcium fluoride, which selectively extracts rare‑earth elements while leaving iron and other metals behind. The salts are then evaporated to enrich the recovered metals before an electrolytic step separates high‑purity neodymium and dysprosium from the molten bath. Laboratory tests achieved recovery efficiencies of about 96% for neodymium and 91% for dysprosium, with purities exceeding 90%.
Because the process uses inexpensive, recyclable salts rather than acids or organic solvents, the researchers believe it could be scaled up with a smaller environmental footprint. The team notes that similar extraction‑evaporation‑electrolysis sequences could be adapted to recycle other valuable metals or reprocess nuclear fuel, supporting a circular economy for critical materials. For industries dependent on rare‑earth magnets, this approach could reduce waste, lower production costs and enhance resource security.
Emmanuel is a committed and safety-driven graduate of Electrical and Electronics Engineering with professional interests in renewable energy systems and power system engineering.
