Life-Cycle Assessment of Nd–Fe–B Rare Earth Magnet Production

Rare-earth elements are strategic materials essential for renewable energy, electronics, and electric mobility. The growing demand emphasizes the need for a sustainable and efficient supply, considering environmental and economic aspects. Among their main applications are neodymium-iron-boron (Nd-Fe-B) permanent magnets, whose production chain presents significant environmental impactsfrom mining to final manufacturing. This study assesses the life cycle of Nd-Fe-B magnets in the Brazilian context, following ISO 14040 and ISO 14044 standards. System modeling was performed in Sankey software, and environmental impacts were calculated using SimaPro 9.1 with data from the EcoInvent database and literature sources. Results indicate that mining is highly impactful, particularly during the roasting stage, due to high energy consumption and emissions of particulate matter and greenhouse gases. In oxide production, leaching and preseparation steps stand out for their use of hydrochloric acid, contributing to marine eutrophication and ionizing radiation. Magnet manufacturing, especially machining, shows major impacts on global warming, ozone depletion, and water use. The study highlights the need for mitigation strategies, such as stricter regulations, circular economy initiatives, and cleaner technologies. Incorporating renewable energy and improving ore processing efficiency can significantly reduce the carbon footprint of Nd-Fe-B magnets.