An average of 1,000 tonnes of neodymium could be harvested each year by recycling offshore wind turbines when they are decommissioned, according to the report by the National Engineering Policy Centre (NEPC). That amount could produce enough magnets to build 1 million electric vehicles (EVs), providing what NEPC leader the Royal Academy of Engineering called a “real opportunity to secure a sovereign capability in manufacturing”.
Published yesterday (1 June) and based on analysis by Warwick Manufacturing Group (WMG) at the University of Warwick, the report found that a single large turbine could provide enough neodymium to produce motors for 12,000 EVs.
Smaller wind turbines are already being decommissioned, but recovery of permanent magnets will start in commercially significant volumes from 2038 onwards, according to the NEPC, which includes IMechE as a partner. The 1,000 tonnes of neodymium that could become available could also be used in ships, planes or heating and cooling systems.
Sourcing neodymium from old turbines could also prove significantly cheaper for UK manufacturers than importing it from China or elsewhere, with an estimated discount of more than 70% against recent prices.
“As the urgent need to decarbonise increases global demand for electric vehicles, developing a supply chain for recycling wind turbines and remanufacturing neodymium magnets could strengthen local manufacturing and support high-paid jobs,” a Royal Academy announcement said.
As an early adopter of wind power, the UK will be one of the first nations to decommission offshore wind turbines on a large scale, once they reach the end of their 15- to 25-year design life. Renewable power technologies could also benefit from neodymium reuse, the report said, providing a potential boost to energy security and sovereignty.
“This is important, since the UK lacks capacity to produce its own neodymium magnets for large wind turbines and currently depends on international supply chains for this critical mineral, amid large increases in demand that are expected to outstrip supply,” the announcement said.
Early action will be needed to secure the strategic and economic advantage, it added. Developing the supply chain would reportedly require new wind turbine designs for easy magnet recovery, new infrastructure – such as port access – for turbine decommissioning, and trade policies to keep neodymium magnets in the UK and to use them for manufacturing and clean energy industries.
“Future supply of neodymium magnets is not guaranteed, but the fact that the UK will have around 1,800 wind turbines installed by 2030 provides a huge opportunity to use the critical minerals within them more sustainably,” said Professor Joan Cordiner, chair of the NEPC Materials and Net Zero Working Group.
“However, we risk future bottlenecks in domestic manufacturing of clean tech if we don’t act now to capitalise on this strategic resource. The UK has a chance to lay the groundwork for recycling its future wind turbines with infrastructure, design standards and regulation. If we fail to do this, we will leave our manufacturing industry more exposed to shifting geopolitical winds.”
Recovery and remanufacturing of magnet assemblies from offshore turbines “could unlock the commercial application of novel electrical machine designs for automotive, aerospace and alternative renewable energy sources like tidal, which have suffered from fragile and volatile supply chains,” said Dr Stuart Bradley, chief engineer of energy technologies at WMG.
Mining and processing new neodymium can also produce significant quantities of radioactive waste, acidifying gases, and liquids and toxic pollutants that frequently pollute local groundwater systems. Mining neodymium also generates far more carbon emissions per kilogram than other metals like iron and steel. Every kilogram of recycled neodymium could prevent the same amount from being mined.
“Remanufacturing neodymium prevents the environmental damage that can be caused by extracting more material and can also provide an economic benefit for the UK,” said Professor Rebecca Lunn, member of the NEPC Materials and Net Zero Working Group.
“Reusing our existing resources means we can reduce carbon emissions and highly polluting waste, and unlock our electric vehicle manufacturing sector, which in turn can improve local air quality and create high-paid local jobs. Developing this supply chain would be a significant boost to the UK’s green transition.”
Want the best engineering stories delivered straight to your inbox? The Professional Engineering newsletter gives you vital updates on the most cutting-edge engineering and exciting new job opportunities. To sign up, click here.
Content published by Professional Engineering does not necessarily represent the views of the Institution of Mechanical Engineers.