Lifelong Learning on Permanent Magnet Value Chain

Rare Earth Permanent Magnet Value Chain

Hereby we offer training for professionals within the thematic orientation Rare Earth Magnets (REM) and Motors, aiming to increase the skills and preparedness for jobs in enterprises that are active along the REM value chain.

The format of the course is blended learning, and it includes both theoretical and practical training to make the learner familiar with the details of the life cycle of Rare Earth Magnets.

The training starts with a digital course “Introduction to Magnetism: Challenges of Rare Earth magnets”. The course is placed on the FutureLearn platform https://www.futurelearn.com/courses/introduction-to-magnetism-the-challenges-of-rare-earth-magnets (module 0) and available for individuals for a fee by the FutureLearn platform. The Basic Concepts of Magnetism course duration is 6 weeks, the study time is 2-4 hours per week. This course is not mandatory but is highly recommended to learners who want to increase their knowledge in magnetism and magnetic materials.

The main part of the course consists of 5 thematic modules, each representing a critical link in the REM value chain.

The duration of the training of each module is one working day (6-8 hours), our students can choose their own course design, either follow the whole course or picking up one or several modules according to their needs.

Module 0: Challenges Of Rare Earth Magnets
Module 1: Rare Earth Element Ores On Mining
Module 2: Current And Novel Production Methods Of Rare-Earth Permanent Magnets
Module 3: Design And Fabrication Of REM-based Devices And Components
Module 4: Rare-Earth Permanent Magnet Recycling
Module 5: Life Cycle Assessment (LCA)

Structure of the Modules

Module 0: Challenges of Rare Earth Magnets

Module 0 is an introductory course that gives basic knowledge on fundamental concepts of magnetism. The module content is fully digitized and placed on the FutureLearn platform. https://www.futurelearn.com/courses/introduction-to-magnetism-the-challenges-of-rare-earth-magnets

It includes the following topics:
  • Origin of magnetism. Magnetic moments of atoms and units.
  • The Periodic Table with focus on 3d and 4f elements
  • Types of magnetic materials: Behaviour of materials in magnetic field. Paramagnets, diamagnets, ferromagnets. Experimental techniques to measure magnetic properties.
  • Hysteresis loops: Saturation, remanence magnetisation, energy product (BH max). Units.
  • Crystal structure vs magnetism. Symmetry, magnetic anisotropy, applications of magnets.
  • 3d vs 4f Metals for industrial magnets. Advantages and drawbacks
  • Introduction to the critical links of Rare Earth Magnet Value Chain.

Module 1: Rare Earth Element Ores In Mining

Lesson 1 Rare Earth Element Exploration (REE): The main aspects of REE ores exploration are introduced, along with cases of study from both inside and outside the EU.

  • Basic concepts in REE mineral resources
  • Exploration and prospecting techniques
  • Mineral characterization of REE samples
  • Mineral deposit models – cases of study

Lesson 2 Rare Earth Element Mining (Part I): A review of mining and metallurgical aspects of REE ores is presented, with a special focus on best available technologies (BAT).

  • Economic aspects in REE Mining
  • Underground mining techniques
  • Open pit mining techniques

Lesson 3 Rare Earth Element Mining (Part II)

  • Mineral Processing Techniques
  • Extractive Metallurgy techniques

Lesson 4 Safety and Environmental Aspects of REE Mining: Quick review of Society & Environment issues in REE ores mining and metallurgy, dealing specifically with the content presented above.

Lesson 5 Social Licence to Operate (SLO) in mining of Rare Earth elements: A practical activity focused on the SLO issues found in REE mining projects at the EU, including a self-critical-analysis exercise.

  • The social paradox of REE mining activities
  • Case of study: Matamulas Project

Lesson 6 Socio-technical toolbox: A practical and ludic activity designed to suggest responsible actions with the aim to change how mining projects are approached, including socio-technical aspects.

Module 2: Current And Novel Production Methods Of Rare-Earth Permanent Magnets (REPM)

Lesson 1 Fully dense REPM production techniques (Part I): The main aspects of the production chain and characteristics of fully dense magnets obtained through sintering routes. These types of magnets can achieve the highest maximum energy product and they are used in high-performance applications such as EVs motors and wind turbine generators, among others.

  • Production of sintered Nd-Fe-B magnets

Lesson 2 Fully dense REPM production techniques (Part II)

  • Production of hot-formed Nd-Fe-B magnets
  • Production of Sm-Co magnets: Sintering

Lesson 3 Bonded REPM production techniques (Part I): Here, we will show the production line and characteristics of bonded magnets. These types of magnets possess a lower energy product than fully dense magnets. On the other hand, they show other advantages such as good mechanical properties and higher electrical resistivity.

  • Compression bonded magnets
  • Injection molded magnets
  • Flexible magnets: extrusion and calendaring

Lesson 4 Bonded REPM production techniques (Part II)

  • Bonded Sm-Fe-N magnets

Lesson 5 Permanent magnet coating: Corrosion protection of REM

Lesson 6 Advanced REPM fabrication techniques (Part I): This activity will cover novel fabrication techniques, mainly focused on metal injection molding (MIM) and additive manufacturing technologies. These fabrication technologies allow for the production of magnets with complex shapes and minimal waste of material.

  • Metal Injection Molding (MIM)

Lesson 7 Advanced REPM fabrication techniques (Part II)

  • Additive manufacturing

Module 3: Design And Fabrication Of REM-based Devices And Components

Lesson 1 Introduction to electric motors: Main aspects of EVs motors and wind turbine generators.

  • Types of electric motors
  • Working principles of different types of electric motors

Lesson 2 Main design equations for permanent magnet electric motors: Open circuit: Basic equations that help to understand how main design parameters affect the performance of the motor.

  • Flux density calculations
  • Torque calculations

Lesson 3 Magnetic materials in the electric motor applications

  • Soft magnetic materials
  • Hard magnets

Lesson 4 Permanent magnet performance calculation: Here we demonstrate how to calculate parameters characterizing performance of permanent magnets.

  • Joule losses (heating)
  • Iron loss (core loss) in electrical machine
  • Length turns, voltage adjustment.

Lesson 5 Demagnetization problems in electric motors

  • Demagnetization curve
  • Calculation of demagnetization curve parameters

Lesson 6 Practical issues on size calculation: Demonstration of practical issues for calculating and optimizing machine dimensions

Module 4: Rare-Earth Permanent Magnet Recycling

Lesson 1 Introduction to Rare Earth permanent magnets (Part I)

  • Rare-earth Elements, REEs: An introduction to REEs, their properties and how they are produced.
  • Why are REEs defined as Critical Raw Materials: In chapter we analyze the importance of REEs and the problems around their supply from primary sources.

Lesson 2 Introduction to Rare Earth permanent magnets (Part II)

  • Main applications of REEs: In this chapter we dive into the many applications of REEs in modern society.
  • Permanent Magnets: Discussion of the types and properties of permanent magnets.
  • Why are permanent magnets important: An economic analysis of the market share of permanent magnets in various fields of their applications.

Lesson 3 Recycling of REE’s from permanent magnets (Part I)

  • Why is recycling important: An economic and technical analysis of the sustainability of permanent magnet recycling.
  • State-of-the-art of the REE Recovery Methods: This is an introduction to the methods used to date for the recycling of permanent magnets.
  • Pyrometallurgy: Here we explain pyrometallurgical methods used to recycle REEs from permanent magnets.

Lesson 4 Recycling of REEs from permanent magnets (Part II)

  • Hydrometallurgy: In this chapter we elucidate hydrometallurgical methods used to recycle REEs from permanent magnets.
  • Challenges: In this chapter we analyze the problems associated with the recycling of permanent magnets.

Lesson 5 Pre-processing methods for REEs recovery from permanent magnets

  • Challenges in the pre-processing of REEs permanent magnets: Here we explain the difficulties in the preparation of permanent magnets for the recycling process.
  • Hydrogen treatment of permanent magnets: Method of preprocessing of magnet scrap with hydrogen.
  • Demagnetization of permanent magnets: Methods for removing the magnetic field from a permanent magnet.
  • Milling process: This chapter analyzes the grinding processes that are used for reduction of the particle size of permanent magnets.

Lesson 6 Hydrometallurgical recovery of REEs from permanent magnets based on MONOLITHOS’ recycling method

  • MONOLITHOS hydrometallurgical Recycling of REEs from permanent magnets: In this chapter we describe the state-of-the-art method developed by Monolithos to recover REEs from permanent magnets.
  • Potential benefits for Environment: A discussion of how the Monolithos method provides a greener alternative to existing recovery processes.
  • Future Perspectives: Here we describe the various ways in which Monolithos will attempt to improve and upscale its REE recycling technology.

Module 5: Life Cycle Assessment (LCA)

Lesson 1 Introduction to LCA: The key aspects related to LCA will be introduced, together with research cases from both inside and outside the EU.

  • General aspects of the LCA approach
  • What is Life-Cycle Assessment (LCA)?
  • LCA Stages & phases
  • Using LCA to meet Sustainability Goals

Lesson 2 Types and Benefits of LCA: A review of the types and benefits of LCA will be presented, with a special focus on the benefits of LCA.

  • Why should we care about LCA?
  • Type of LCA
  • Benefits of LCA
  • LCA Case Studies
  • Support Product Design & Marketing

Lesson 3 Sustainable Recycling of Permanent Magnets: In this activity, the types/key properties/applications of permanent magnets will be shortly overviewed. The importance of recycling will be emphasized in connection to modern recycling methods.

  • Understanding of permanent Magnets
  • Environmental Impacts and Benefits of Permanent Magnet Recycling
  • Recycling Technologies and Best Practices

Lesson 4 Life Cycle Assessment of Magnets and Environmental Impacts: The Life Cycle Assessment of Magnets and Environmental impacts will be presented in this activity.

  • Environmental Improvement Strategies
  • Environment, Health and Safety (EHS) Assessment
  • REEs as key CRMs for the future of renewable energy and smart mobility in the EU
  • Future Trends and Innovations
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