Dynamic life cycle assessment of NdFeB magnet production – case for carbon emission intensity

NdFeB magnets are critical to many clean energy applications, such as electric vehicles and wind turbines. However, rare earth elements (REEs) used in NdFeB magnets carry considerable environmental burdens (including carbon footprint) due to direct emissions and intensive energy and chemical consumption in all major process steps. This study conducts a dynamic LCA (DLCA) with a focus on carbon footprint considering ore grade decline, best available (control) technology (BAT/BACT), recycling rate, and RE ore type/origin/processing pathways. The dynamic LCI is compiled based on the critical material life cycle assessment tool (CMLCAT), plans and policy from the Chinese REEs company, governments, and potential REEs mining projects worldwide. The results show that 90% contribution of GHG emission is from RE metal, and the environmental burden will be significantly decreased by implementing a higher magnet recycling rate and utilizing RE metal from low carbon pathways, e.g., Mount Weld in Australia.