Belfast recycles rare earths for EV motors

Belfast-based Ionic Technologies is scaling a circular supply chain that recycles end-of-life permanent magnets into high-purity rare earth oxides for electric motors.

Backed by £11 million of UK Government funding for the CirculaREEconomy project, the company uses a proprietary hydrometallurgical process to produce separated rare earth oxides exceeding 99.5% purity—material chemically equivalent to mined and refined product and suitable for all magnet grades. Each EV motor requires roughly 1.4 kg of critical rare earths; Ionic’s demonstration plant currently yields about 10 tonnes per year and the firm plans a 400 tpa commercial plant to be delivered within roughly two years, targeting design capacity across Belfast by 2030.

The approach offers both supply resilience and lower emissions: peer-reviewed analysis indicates up to a 61% CO2 reduction versus primary mining. Demand has accelerated since China tightened export controls on key elements such as neodymium, praseodymium, dysprosium and terbium. Major OEMs (including Ford, Bentley and Wrightbus) and supply-chain partners are involved in testing and scale-up.

Ionic’s process accepts damaged, oxidised or coated magnets from sources ranging from wind turbines to hard drives, and plans further plants internationally, including the US, to reduce reliance on primary mining and fragile supply chains.