HyProMag USA Launches Delivery of Rare Earth Permanent Magnet Recycling and Manufacturing Equipment

en.Wedoany.com Reported - On November 9, HyProMag USA, an American rare earth magnet manufacturing company, announced that its rare earth permanent magnet recycling and manufacturing facility in Northlake, Texas, has received its first batch of large-scale process equipment. The project is being built on approximately 128,000 square feet (about 11,900 square meters) of plant space, primarily equipped with hydrogen processing equipment for scrap magnets and magnet processing and finishing equipment. The company plans to commence magnet cutting and finishing operations in the first half of 2027, and to commission the integrated recycling and manufacturing system in mid-2028. At full capacity, the facility is planned to produce approximately 1,526 tonnes of saleable magnetic material per year.

The project is located at the Ironhead Commerce Center in Denton County within the Dallas–Fort Worth metropolitan area. HyProMag USA secured a long-term lease agreement for the plant in December 2025, with a lease term of 25 years. The facility will be built as a production base integrating scrap rare earth magnet recycling, material processing, magnet processing, and finished product manufacturing. Power supply capacity has been secured for the project, environmental permitting is being advanced by Weston Solutions, and the selection of a construction contractor is still underway.

The equipment configuration centers on magnet recycling and remanufacturing processes. The previously announced long-lead equipment procurement scope includes three hydrogen processing vessels for magnet scrap, as well as magnet processing and finishing equipment. Hydrogen processing technology reacts hydrogen gas with neodymium-iron-boron (NdFeB) magnet material, embrittling the magnet structure and facilitating subsequent processing, thereby recovering magnetic material from end-of-life motors, electronic devices, and other magnet-containing components. Unlike the traditional production pathway of extracting rare earths from ore followed by smelting and magnet manufacturing, this process directly uses scrap magnets as feedstock, shortening the magnet recycling and remanufacturing flow.

In the magnet processing stage, the facility will be equipped with cutting and finishing equipment to perform dimensional machining, surface treatment, and product specification adjustment of magnet blocks, meeting different customers' requirements for dimensions, tolerances, coatings, and magnetic properties. The company's previously announced phased construction plan indicates that magnet cutting and finishing equipment will be prioritized for commissioning in the first half of 2027, with initial operations planned to use up to 20 tonnes of magnet blocks supplied by HyProMag Group facilities in the United Kingdom and Germany for processing production, and to provide finished magnet samples meeting requirements to U.S. customers.

The complete recycling and manufacturing system is planned to enter the commissioning phase in mid-2028, at which point scrap magnets and manufacturing scrap collected domestically in the United States will be gradually integrated, producing recycled NdFeB magnetic material through processes including hydrogen processing, material separation, magnet processing, and subsequent property treatment. The project plan also includes grain boundary diffusion processes to improve magnet performance metrics such as coercivity. The company expects that after completion of the second-phase construction, the Northlake facility will achieve an annual output of approximately 1,526 tonnes of saleable magnetic material, including finished magnets, sintered magnet blocks, alloy powder, and machining scrap.

HyProMag USA is collaborating with American recycling company Intelligent Lifecycle Solutions to establish pre-processing operations in South Carolina and Nevada, collecting end-of-life hard disk drives and other electronic devices containing NdFeB magnets. The pre-processing facilities have already installed third-generation hard drive magnet separation equipment, with plans to further expand the feedstock scope to electric motor rotors, wind turbine magnets, speaker assemblies, and decommissioned MRI equipment. Pre-processed magnet materials will be sent to the central Texas facility for subsequent recycling and manufacturing.

The project is expected to create approximately 100 direct jobs. In addition to the Northlake facility, HyProMag USA announced in October 2026 a pre-feasibility study for a multi-facility expansion in the United States, planning to add three production facilities and a centralized finishing center beyond the first Northlake plant, with the goal of achieving approximately 4,192 tonnes of NdFeB magnet output and approximately 6,000 tonnes of saleable material output per year by 2034.