UK-based engineering firm, GreenSpur Wind, and US magnet manufacturer, Niron Magnetics, have announced a successful collaboration to develop rare earth element (REE)-free wind turbine generators.

The new 15-MW generators will be powered by Niron’s proprietary “Generation 1 Clean Earth Magnet” which is based on iron and nitrogen. This FeN permanent magnet, coupled with GreenSpur’s updated generator design is said to offer higher magnetization at a lower cost, compared to previous designs using other ferrite magnets. With detailed testing in place and approvals by the Offshore Renewable Energy (ORE) Catapult, the next step for the parties will focus on commercialisation.

Rare earth permanent magnets are used extensively in many products, including advanced electronics, electric vehicles (EVs), and direct-drive permanent magnet generators (DDPMGs) used in wind turbines. Compared to gear-drive turbines, DDPMGs are generally the preferred choice for offshore wind applications because they offer a large power capacity, are more compact and require less maintenance. These DDPMGs incorporate some of the largest volumes of neodymium iron boron (NdFeB) magnets per unit but the future role of these magnets is heavily impacted by the vulnerable China-dominated REE supply chain.  As a result of long-term concerns over stable, secure access to REEs, many industries are either working on reducing the use of REEs, recycling spent products or developing REE-free alternatives. While some of these substitutions offer good levels of efficiency, they are still outcompeted by REE-based products in several industries. For instance, REE magnets used in EV drivetrains remain the superior choice.

Given the increased focus on climate change, many governments are implementing green strategies and are shifting focus towards clean energy technologies, like wind energy and EVs. With the growing demand for these technologies, REE magnets are also projected to see significant growth. Even though the long-term inclusion of REEs in wind energy remains open for debate, NdFeB growth is still predicted to be bolstered by electrification, which is also set to become its single largest application. With respect to the wind industry, the role of REEs will ultimately be shaped by the urgency of future energy policies, new supply sources and the advantages REE-based technology may have over alternatives.