📚 Part of a Bigger Series
x.com/roblun1/status/2033432…
This is Ionic Technologies Magnet Recycling breakdown which is part of my ongoing series on the new magnet‑recycling and separation ecosystem — covering how different technologies and business models stack up across Ionic Technologies, Cyclic Materials, REEcycle, ReElement, Ucore, and HyProMag, and will be adding Caremag/Carester comparing product purity, processing routes, scalability, and where each fits in the emerging circular magnet supply chain.
The Last Part of the Magnet Recyclers in my series
💎 Ionic Technologies & Multifunctional Amide Ionic Liquids
🧪 INTRO — MAIL: The Belfast chemistry quietly solving the West’s magnet problem
85% of rare earth processing and magnet manufacturing still sits in China. Export controls on Dy/Tb in 2025 showed how fragile that is.
In Belfast, Ionic Technologies (ASX:
$IXR) has spent a decade building something radically different:
Multifunctional Amide Ionic Liquid (MAIL) technology that can separate Nd/Pr in one circuit and Dy/Tb in another — from both end‑of‑life magnets and mixed rare earth carbonate (MREC).
Here’s how it works and why it matters. 🧵
🧬 1️⃣ The Chemistry — Engineered Ligands, Not Kerosene
Traditional rare earth separation uses organophosphorus extractants dissolved in kerosene or n‑heptane, running through hundreds of mixer‑settlers to tease apart Nd, Pr, Dy, Tb. Dirty, sprawling, and dangerous — and China spent 30 years perfecting it.
MAIL flips that on its head.
Uses task‑specific ionic liquids — salts that are liquid near room temperature.
Attaches multifunctional amide ligands precisely engineered to grab specific lanthanide ions.
Achieves selectivity ~100x higher than legacy extractants, so the whole separation happens in ~15 steps instead of >150.
The solvent is non‑volatile and non‑flammable — no kerosene, no explosion risk.
The ionic liquid doesn’t get consumed; it’s recycled loop‑after‑loop as a capital asset, not a throw‑away reagent. ⚙️
🧪 A decade in the lab, 30 months in continuous operation
MAIL isn’t a concept on a whiteboard — it’s the result of 10 years of ionic‑liquid research at Queen’s University Belfast, spun out as Seren Technologies in 2016 and acquired by Ionic Rare Earths in 2022.
Since early 2024 the Belfast demonstration plant has been running 24/7, taking in batches of end‑of‑life NdFeB magnets and production swarf and consistently outputting >99.5% purity Nd, Pr, Dy and Tb oxides for partners like LCM, Ford and VAC.
That continuous 30‑month operating history under industrial control systems is what turns MAIL from an interesting chemistry paper into a bankable midstream separation platform.
♻️ 2️⃣ Two Circuits — Nd/Pr and Dy/Tb from Any Feedstock
MAIL is built around two parallel separation circuits:
A light‑rare‑earth (LREE) circuit tuned for Nd/Pr
A heavy‑rare‑earth (HREE) circuit tuned for Dy/Tb/Ho
Feedstock can be:
End‑of‑life NdFeB magnets from EVs, wind turbines, electronics, production swarf
MREC (Mixed Rare Earth Carbonate) from primary mines like Makuutu (Uganda) or Colossus (Brazil)
The front‑end changes, the separation backbone doesn’t:
Magnets → demagnetised, stripped, crushed, dissolved
MREC → leached and clarified
Both become a mixed REE solution that goes through MAIL → Nd, Pr, Dy, Tb split into separate oxide streams at >99.5–99.9% purity.
One platform, two feeds, four critical oxides. 🧲
🏭 3️⃣ Belfast Demo → 400 tpa Plant
Ionic’s tech isn’t just lab‑scale — Belfast’s demonstration plant is running 24/7:
10 tpa early pilot → now 30 tpa demonstration plant in Titanic Quarter
Producing >99.5% pure Nd₂O₃, (NdPr)₂O₃, Dy₂O₃, Tb₄O₇ from real magnet scrap
Independent LCA (Minviro) shows up to 61% lower CO₂ vs typical primary routes, especially for Dy oxide.
Next step: 1,200 tpa magnet feed / 400 tpa REO commercial plant in Belfast, with a £12m Offer in Principle under the UK’s £2.5bn DRIVE35 programme. Capex: £85m; IXR is now lining up strategic equity alongside UK grants.
First production target: within ~2 years of final investment decision. ⏳
🧱 4️⃣ Feedstock Locked In — EMR, OEMs & BGS Data
A recycling plant lives or dies on scrap — and on knowing where future scrap will come from. Belfast has both:
♻️ EMR — leading UK/EU recycler (150 yards), bringing EOL EVs, wind turbines and industrial scrap; projects like REAP, SCREAM, Re‑Rewind and the £11m CirculaREEconomy (CREEM) programme are explicitly configured to feed Ionic’s Belfast hub.
🧲 VAC & GKN — European magnet makers whose production swarf, offcuts and rejected parts are ideal high‑grade feedstock for MAIL.
🚗 Ford Halewood — up to 420,000 e‑drive units/year, each using roughly 1–2 kg of NdFeB magnets; manufacturing offcuts and warranty returns are designed to loop back into Belfast.
🚍 Bentley & Wrightbus — smaller volumes but very high‑value scrap and EOL flow from premium EV and hydrogen bus platforms engaged in the same circular programme.
🌬️ BGS & UK Technology Metals Observatory — new interactive maps and material‑flow models quantify Nd, Pr, Dy, Tb stocks in UK wind farms and EV motors, including when each wind farm is likely to hit end‑of‑life and become magnet feedstock.
sciencedirect.com/science/ar…
bgs.ac.uk/news/new-interacti…
techmetalsobservatory.org/ci…
On the back of this work, I’ll be running a dedicated series on UK feedstock availability — using the same approach I used for profiling magnet recyclers — to track how quickly those in‑use stocks (EVs, wind, HDDs, industrial motors) can realistically support Belfast and the wider UK circular REE industry.
Combined consortium supply today is already ~1,000–1,850 tpa of NdFeB magnet material, more than enough to saturate Ionic’s 1,200 tpa magnet‑feed Belfast design capacity, with BGS/TechMetals data highlighting a much larger wave of wind‑turbine and EV magnets arriving through the 2030s.
🔍 And just like every other magnet recycler, feedstock is the whole ballgame.
The chemistry is proven and the grants are real, but long‑term success for Ionic, HyProMag, Cyclic, ReElement, REEcycle, Caremag and the rest will come down to one thing: who can lock in sustained, high‑grade magnet and MREC supply at scale as EVs, wind turbines and data centres hit end‑of‑life through the 2030s. My upcoming UK feedstock series will dig into exactly that.
🌍 5️⃣ Partners & Grants — UK’s Chosen Midstream Platform
The UK and EU have quietly picked their midstream horse:
~£5m in direct UK grants to Ionic (TDAP, SuRV, CLIMATES, REEVALUATE) plus leadership role in the £11m CirculaREEconomy (CREEM) consortium.”
£12m DRIVE35 Offer in Principle for Belfast commercial plant capex
Backed across 8 major reports (Frazer‑Nash, NAO, IEA, MPI, etc.) as the leading example of magnet and wind‑turbine recycling in the UK’s critical minerals strategy.
CirculaREEconomy consortium: EMR, LCM, VAC, GKN, Ford, Bentley, Wrightbus, BGS.
This isn’t a science project any more — it’s the UK’s reference midstream separation platform for EVs, wind and defence. 🇬🇧
🌐 6️⃣ IP Moat & Global Roll‑Out
Ionic’s MAIL platform is heavily patented:
Chemistry & separation families: WO2018109483A1, US11401579B2, US11958754B2, US12024756B2
Upstream pre‑treatment for MREC and variable feeds: GB2412427.3, GB2412428.1, GB2412430.7
Expansion nodes:
🇺🇸 Missouri (US Strategic Metals) — MAIL recycling & separation co‑located on a permitted multi‑metal platform under the US–Australia critical minerals framework.
🇧🇷 Brazil (Viridion JV with Viridis Mining & Minerals) — MAIL refinery recycling hub tied to the Colossus ionic clay project, aiming to support 100 tpa NdFeB at SENAI’s LabFab line by 2026.
viridionre.com/
Belfast is the template — Missouri and Minas Gerais are the next bricks in a global MAIL network. 🌎
🎯 7️⃣ Why MAIL Matters for Investors
✅ Feed‑agnostic: handles both EOL magnets and MREC from multiple deposits.
✅ Purity & yield: 89–90% recovery, >99.5–99.9% purity Nd/Pr/Dy/Tb/Ho.
✅ Carbon & safety: up to 61% lower CO₂; non‑volatile, non‑flammable solvents.
✅ Capital efficiency: ~15 stages vs >150, closed‑loop solvent turns OPEX into CAPEX.
✅ Strategic fit: explicitly name‑checked across UK & IEA policy reports as the model for magnet and wind‑turbine recycling.
For anyone tracking ex‑China magnet supply chains, MAIL in Belfast is no longer optional homework — it’s required reading. 🧠🧲
@IONICTECH_UK @IONIC_RE @timhorizonmet @EMRGroupLimited @LCM_Metals #VAC @Wright_bus @BentleyMotors @QUBelfast @CMA_Minerals @ChrisMcDonaldMP @IEA $IXR #IonicTechnologies #MAIL #RareEarths #NdFeB #MagnetRecycling #CriticalMinerals #EVSupplyChain #WindEnergy #DefenceSupplyChain #Belfast #DRIVE35 #CirculaREEconomy #IonicLiquids #GreenChemistry #SupplyChainSovereignty @roblun1 @IXR2THAMOON
🧲♻️ Magnet Recycling Spotlight
🚀 Over the next few weeks this series will cover different magnet‑recycling technologies and business models across players like, Ionic Technologies, Cyclic Materials, REEcycle, ReElement, Ucore and HyProMag, comparing product purity, processing routes, scalability and where each fits in the emerging circular magnet ecosystem.
🧲 Not all magnet recycling is created equal. These 6 companies represent 6 distinct technology business model combinations — and together they map the entire Western supply chain response to China's rare earth dominance, the 6 pure-play recyclers🧵👇
Tier 1 — Pure-Play Magnet Recyclers (the 6)
Ionic, Cyclic, HyProMag, ReElement, REEcycle, Ucore
→ Magnet recycling IS their entire business model.
Solvay lies in between, accepts recycled feedstock as one input stream among several.
REEtec of Norway sits alongside Solvay, it is building a large-scale separation facility at Herøya funded by LKAB specifically to accept recycled and mined mixed REO feeds and convert them into separated oxides for European magnet makers.
Tier 2 — Integrated Players with Recycling Arms
MP Materials, USA Rare Earth/LCM, Energy Fuels, Carester, Momentum, Geomega, S
→ Recycling is a strategic component within a larger mine-to-magnet or multi-metal business
Tier 3 — Established Asian Incumbents
Shin-Etsu, Proterial, Santoku
→ Commercial at scale for 15 years but within closed Japanese supply chains — the benchmark the West is trying to match
1️⃣ Ionic Technologies 🇬🇧
Long-loop Solvent Extraction using MAIL™ (Multifunctional Amide Ionic Liquids & Ligands)
→ Separated REOs (>99.9% purity) | Continuous processing | Lowest variability | Feed-agnostic
✅ Published LCA
✅ Feasibility Study
✅ UK Govt £12M Grant
✅ FORGE designated
The precision specialist — highest purity, proven IP, ready to license globally
2️⃣ Cyclic Materials 🇨🇦
Medium-loop Leaching (MagCycle REEPure)
→ Mixed Rare Earth Oxide (rMREO) | Hub & spoke model | Real plant operating NOW
✅ US$162M raised
✅ South Carolina plant confirmed (2028)
✅ VAC Solvay offtakes signed
The volume play — feedstock-agnostic, massively funded, scaling fast
3️⃣ REEcycle 🇺🇸
Medium-loop Leaching using Metal-Organic Frameworks (MOFs)
→ Rare Earth Formates | 99.8% recovery efficiency | Low-temperature chemistry
⚠️ Pilot stage | No LCA or feasibility study published | Dependent on downstream separators
The chemistry innovator — compelling science, still proving economics at scale
4️⃣ ReElement Technologies 🇺🇸
Long-loop Continuous Chromatography (pharmaceutical-grade)
→ Separated REOs (99.999% purity) | Marion Indiana Supersite targeting 10,000 tpa
✅ US$200M equity facility
✅ DoD qualified
✅ POSCO ERI feedstock partnerships
The purity champion — highest specification product, aggressive US scaling
NASDAQ: AREC
5️⃣ HyProMag 🇬🇧🇺🇸
Short-loop Hydrogen Decrepitation (HPMS)
→ Recycled NdFeB Alloy Powder | Re-sintered directly into new magnets
✅ Commercial Birmingham plant OPEN Jan 2026 ✅ Dallas-Fort Worth Hub secured
✅ ISO LCA: 85% lower carbon vs primary mining | 4,600 tpa USA target by 2029
The speed champion — shortest loop, lowest carbon, first to commercial in UK
TSXV/AIM: MKA
6️⃣ Ucore Rare Metals 🇨🇦🇺🇸
Long-loop RapidSX™ (Advanced Column Solvent Extraction)
→ Separated Heavy Light REOs (Dy, Tb, Sm, Gd, Nd, Pr) | 3X faster than conventional SX
✅ US$22.4M DoD contract
✅ 5,700 hrs proven operation
✅ Louisiana SMC commercial 2026
The heavy REE specialist — defence-critical SmCo magnets, filling the most acute Western gap
TSXV: UCU
The Western magnet recycling ecosystem is deliberately segmented. End-users — magnet makers, OEMs, and defence primes — will choose based on four dimensions:
🔬 Product spec — Separated oxide (Ionic, ReElement, Ucore) vs mixed oxide (Cyclic, REEcycle) vs alloy powder (HyProMag)
🌍 Geography — Feedstock proximity energy costs geopolitical mandate (US IRA, UK DRIVE35, EU CRM Act)
🌱 Sustainability — LCA proof required by OEMs (Ionic ✅ HyProMag ✅ others pending)
⚡ Scale timing — Who can deliver volume WHEN the EV and wind ramp demands it (2026–2030 critical window)
The US government is deliberately not picking one winner — it is funding across all three loops:
🔬 Long-loop separated REO → Ucore (DoD, US$22.4M), USA Rare Earth (Commerce, US$1.6B LOI)
🧪 Medium-loop recycling → REEcycle (DoD DPA Title III, US$5.1M)
🏭 Full supply chain → DOE US$134M open program US$1B broader critical minerals
The Demand Explosion
Adamas forecasts the global magnet rare earth oxide market will increase more than 7-fold by 2040, from US$9.7 billion today.
Critically, they project approximately US$7.3 billion worth of magnet REO demand will go completely unsatisfied by 2040 if supply doesn't grow beyond their base case — driven specifically by Dy, Tb, and NdPr undersupply.
adamasintel.com/global-marke…
@IONIC_RE @IONICTECH_UK @ussmetals @anduriltech @CMA_Minerals @IXR2THAMOON @timhorizonmet @ThalesDefence @northropgrumman @LockheedMartin @BoeingDefense @DeptofWar @DoWCTO @Viridis_VMM @ucore @LCM_Metals @CyclicMaterials
@MPMaterials @ReecycleInc @SolvayGroup @ReElementTech @EMRmetal
#VIRIDION @EU_Commission @ENERGY @VulcanElements @RE_Exchanges @DiscoveryAlert @USRareEarths
@DeptofWar #MagnetRecycling #RareEarths #CriticalMinerals #CircularEconomy #SupplyChain #Sustainability #EVs #WindEnergy #NdFeB #IonicTechnologies #CyclicMaterials #HyProMag #ReElement #Ucore #REEcycle #MAIL #GreenTech