Clean Earth Magnet: Swapping rare earth for innovation

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  Quantumrun Foresight
• May 28, 2024

Insight summary

New technologies are emerging to replace rare earth materials in generators with lighter and more efficient alternatives, aiming to overcome the current limitations of supply and environmental impact. These advancements have shown promising results in reducing generator weight significantly, which could drastically reduce costs and structural challenges in the offshore wind sector. The move towards rare earth-free magnets opens new opportunities for innovation and job creation and promises a future where renewable energy is more accessible and less dependent on volatile materials.

Clean Earth Magnet context

Companies like GreenSpur Wind and Niron Magnetics are developing rare earth-free generators that promise to offer a lighter and more efficient alternative. This innovative approach is driven by the need to mitigate the challenges associated with the volatility and supply chain constraints of rare earth materials, which are currently essential components of conventional turbines. GreenSpur Wind, leveraging a unique axial-flux design alongside Niron Magnetics' proprietary Clean Earth Magnet technology based on iron nitride, aims to eliminate reliance on these scarce materials, ensuring a sustainable and stable supply for the industry.

The collaboration between these companies has yielded promising results, with GreenSpur developing a 15-megawatt (MW) wind turbine generator. The new generator design has demonstrated a remarkable 56 percent reduction in mass, addressing past concerns regarding the weight of rare earth-free solutions and their implications for structural support and cost. Such advancements are crucial for offshore wind, where generator weight is pivotal in overall turbine design and installation costs.

The implications of this technology extend beyond the offshore wind industry, promising broader applications in sectors seeking sustainable and efficient alternatives to rare earth-based magnets. Niron Magnetics' approach to producing high-performance iron nitride magnets could also transform the automotive and consumer electronics industries. With the backing of substantial funding and research, including collaboration with the University of Minnesota and several US Department of Energy national research facilities, this technology is poised for commercialization. 

Disruptive impact

The shift towards rare earth-free magnet technologies could lead to new job opportunities and skill requirements, focusing on the production, maintenance, and innovation of these new generator technologies. As these rare earth-free solutions become more prevalent, professionals may need to adapt by gaining expertise in novel materials and manufacturing processes, ensuring they remain relevant in an evolving job market. Moreover, this shift could also make renewable energy more accessible and cost-effective, directly impacting consumers by potentially lowering electricity costs and increasing the adoption of clean energy solutions.

Manufacturing and renewable energy firms will likely need to rethink their supply chains, moving away from rare earth elements towards more abundant materials like iron and nitrogen, which could alleviate supply chain risks and reduce costs. This change may also encourage product design and development innovation, pushing companies to explore new applications for rare earth-free magnets beyond wind turbines, such as electric vehicles and consumer electronics. Strategic adjustments in operations and product offerings could position these companies as leaders in sustainable technology, enhancing their market competitiveness and aligning with increasing consumer demand for environmentally friendly products.

By supporting research and development in rare earth-free technologies, governments can spur innovation and reduce their countries' dependence on imported rare earth elements, enhancing national security. International policies might also shift, with countries collaborating to establish standards and regulations that promote using sustainable materials in technology. This trend could also influence local economic development strategies, encouraging investment in industries that produce and utilize rare earth-free technologies.

Implications of Clean Earth Magnet

Wider implications of Clean Earth Magnet may include: 

• Increased use of clean earth magnets in renewable energy technologies, reducing reliance on fossil fuels and lowering greenhouse gas emissions.
• Shift in global trade patterns, with countries rich in iron and nitrogen resources gaining economic advantages over those with rare earth mineral reserves.
• Enhanced energy security for nations, diminishing the geopolitical tensions associated with rare earth element supply chains.
• Acceleration of EV adoption due to more affordable and efficient motors, contributing to cleaner urban environments.
• Potential disruption of traditional mining industries, prompting a need for re-skilling and vocational training programs for affected workers.
• Growth in investment and innovation within the recycling sector, focusing on recovering and reusing iron and nitrogen from obsolete products.
• Environmental benefits from reduced mining and processing of rare earth elements, leading to lesser water pollution and habitat destruction.

Questions to consider

• What steps can you take to support and benefit from the transition to more sustainable consumer electronics and appliances?
• How might changes in global trade dynamics, due to shifts in material sourcing for technology, impact your country’s economy?