Project
Objectives
Increase the recovery of REE and optimise sorting of recycled EoL PMs (OB1)
- Apply different methods for sorting, characterising and dispatching the EoL
PMs for recycling. - Refine sorting of EoL PMs, allowing a higher recovery rate of all the PMs’ alloy elements.
- Transform used magnets into secondary raw materials (powders) efficiently.
- Optimise short-loop recycling process, avoiding downcycling of HREE and PM alloys.
Establish new magnet manufacturing processes to increase resource efficiency (OB2)
- Source secondary materials from recycling, supplemented by primary sources where necessary.
- Implement new PMs with a higher substitution rate of critical REE, utilising more common REE such as Cerium and Lanthanum while minimising the HREE (Dysprosium, Terbium) content.
- Develop a new near-net-shape manufacturing process to minimise material losses.
Design advanced magnet shapes and rotor designs for EVTMs (OB3)
- Retrofit existing rotors with PIM-manufactured PMs.
- Create new optimised rotors to maximise the benefits of PIM technology.
- Reduce the use of magnets and REE in EVTMs.
- Achieve a weight reduction of 20% in PM mass at the same power as the reference EVTM.
- Increase EVTM recyclability score by optimising their design for disassembly
Demonstrate the MAGELLAN solution for highly recyclable PMs, brought to TRL7(OB4)
- Demonstrate PIM magnet and associated production tooling (moulds) maturity.
- Compare the newly designed EVTM rotor against a state-of-the-art reference retrofitted rotor currently in mass production EVTMs.
- Present experimental results from component to system level validation on the EVTM test-bench.
- Assess the recyclability of the MAGELLAN-produced PMs within an EVTM demonstrator.
Demonstrate the sustainability and business benefits of the MAGELLAN solution (OB5)
- Run an Environmental, Social, and Governance (ESG) cycle in parallel with the industrial cycle.
- Prove the financial feasibility with comprehensive business plans.
- Demonstrate environmental sustainability (LCA).
- Conduct studies for optimal and responsible REE sourcing.
- Compare the MAGELLAN solution against current scenarios for PM production and recycling.
- Generate guidelines for responsible use of REE in secondary and primary raw materials.