Ionic Rare Earths Ltd. (IonicRE) has demonstrated a complete, circular supply chain for high-performance electric motor rare earth permanent magnets (REPM), proving that recycling technology can supply Western supply chains.
The breakthrough, led by Ionic’s subsidiary Ionic Technologies, is a collaboration with industry giants Less Common Metals (LCM), GKN, and Ford UK.
The project successfully produced high-purity rare earth oxides (REOs) from recycled magnets and secondary materials, which were then converted into magnets for Ford’s e-motor rotors.
Rigorous durability testing conducted at Ford’s R&D facility in Dunton, UK, confirmed that the recycled rotors performed with results equivalent to those manufactured using traditional production magnets.
IonicRE Managing Director Tim Harrison welcomed the project’s success as a technological pivot for Western supply chains.
“Utilising made-in-Belfast technology, Ionic Technologies was the first producer of recycled, individually separated magnet REOs in the Western world, and this now proves that its long-loop recycling technology can supply Western supply chains for the most demanding applications,” Harrison said.
“We have demonstrated that a circular supply chain is not just a good idea, it is something that we can enable right now from our demonstration plant in Belfast.”
The project, dubbed CLIMATES and supported by the UK government, marks a step toward sovereign resource security.
The UK’s Critical Minerals Strategy aims to have 20 per cent of mineral needs met through recycling by 2035, compared to current domestic production, which accounts for just 6 per cent.
The proprietary hydrometallurgical process used by Ionic allows for the extraction and separation of individual elements, neodymium, dysprosium, and terbium, to purities exceeding 99.5 per cent.
The technology is also agnostic, meaning it can process variable-grade, oxidised, or coated magnets that were previously considered waste.
Ford of Britain’s Dennis Witt noted that the recycled magnets met rigorous commercial standards on the first attempt.
“While this is currently a testing project rather than mass production, it con=rms that a circular supply chain for rare earth elements is a reality, offering a sustainable path forward without compromising vehicle performance,” Witt said.
As IonicRE moves toward a final investment decision for a commercial-scale plant, the company will continue developing relationships with interested industry partners and offtake agreement.
IonicRe is also continuing discussions with potential strategic investors to secure the remaining equity capital required for the £85 million project, supporting FID for the commercial plant.
