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Case Study: Extracting Rare Earth Elements from End-of-Life Magnets

HyProMag Case Study: Extracting Rare Earth Elements from End-of-Life Magnets

As global demand for rare earth elements continues to grow, finding sustainable ways to recover and reuse these valuable materials has never been more important. Millions of electronic devices, motors and industrial components reach end-of-life every year, yet many still contain recoverable Neodymium Iron Boron (NdFeB) magnets, a critical material for modern electrical technologies.

Recovering this material efficiently has long been a challenge. So when HyProMag (working in partnership with the University of Birmingham) approached us in search of a furnace to support the industrialisation & commercialisation of their innovative process, it presented an exciting opportunity to contribute to a groundbreaking local advancement and support the next stage of sustainable manufacturing.

Read on to find out more.

Who are HyProMag?

HyProMag is a University of Birmingham spin-out based at Tyseley Energy Park, a low carbon and energy innovation hub in Birmingham, UK, based on the site of a former wire manufacturer and client of Riley Surface World . HyProMag’s  mission is simple: develop more efficient supply chain for recycling rare earth magnets.

Through research and innovation, HyProMag has already processed more than 3,500 magnets from waste sources, producing high purity recycled material and progressing to testing the material for commercial validation.

What is Hydrogen Processing of Magnet Scrap (HPMS)?

HyProMag’s breakthrough technology, Hydrogen Processing of Magnet Scrap (HPMS), is transforming magnet recycling.

By exposing scrap magnets to hydrogen at atmospheric pressure and room temperature, the magnets safely break down into a demagnetised powder. This allows the NdFeB material to separate cleanly from coatings, adhesives and housings that previously made recovery difficult.

The result is a high purity powder that can be further refined and reused in new magnet production, reducing waste and dependence on newly mined materials.

Why HPMS Matters for Manufacturing?

HPMS delivers significant environmental and commercial benefits:

  • Up to 90% lower CO₂ emissions compared with mining and refining virgin materials
  • Reduced reliance on overseas supply chains
  • Lower material costs
  • Greater sourcing reliability
  • A sustainable use for growing volumes of electronic waste

The process is also helping restore rare earth magnet production to the UK for the first time in 25 years, supporting sectors including aerospace, automotive, medical, robotics, defence and renewable energy.

Riley Surface World’s Involvement

Once the R&D phase was complete, HyProMag needed to scale production for commercial output, requiring specialist heat treatment equipment to support the next stage.

They approached Riley Surface World seeking a furnace capable of:

  • Minimum temperatures of 750°C
  • Handling up to 100kg of NdFeB powder per batch
  • Heavy-duty, reliable operation

Following a visit to our warehouse, HyProMag selected one of our used 1100°C industrial furnaces, featuring a large internal chamber (1060mm x 1470mm x 660mm). The system provided the performance, capacity and cost effectiveness needed to help accelerate their scale up plans towards processing 100 tonnes of material.

Supporting Innovation With the Right Heat Treatment Solutions

As manufacturing evolves and new sustainable technologies emerge, Riley Surface World continues to supply the dependable heat treatment equipment that makes innovation possible.

Our range of quality furnaces & ovens offers proven performance at competitive prices, helping businesses scale efficiently without long lead times. Alongside this, our growing new machinery catalogue continues to evolve in line with the latest technologies and customer demands.

If you’re expanding your heat treatment process or developing something new, our team is ready to help you find the right solution.

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