Objectives of the BEETHOVEN Project

To design and produce BEETHOVEN materials and magnets. The project will focus on the following promising materials, exploring best upscaling routes of the selected magnets by means of sustainable technologies, aiming at energy products of the resulting improved PMs of at least 55 kJ/m3:
• High-entropy-alloys (HEAs) (REE-lean magnets): We will develop HEAs that partially substitute REE in Nd2Fe14 B.type structures. Identified as next-generation materials in the Advanced Materials 2030 Initiative Roadmap (https://www.ami2030.eu/), the objective is that the energy product of the resulting improved magnets is in the range of 55-220 kJ/m3.
• W-type sintered ferrites (REE-free magnets): Their large magnetocrystalline anisotropy and high cation tunability makes these materials promising to cover the huge gap in performance between REE magnets and REE-free magnets, with a theoretical (BH)max = 68 kJ/m3.
• Composite ferrites (REE-free magnets): We will develop composite magnets based on the novel concept of anisometric ferrite-based composites where a 20% increase in Br and 50% improved energy product with respect to pure ferrite magnets has been demonstrated.

To demonstrate successful substitution of REE magnets for BEETHOVEN magnets in green applications: Based on patented and demonstrated technologies, energy generation, energy storage and transportation prototypes with comparable performance to REE options will be designed and constructed:
1. A prototype of a REE-free-lean wind turbine with 3-5 kW nominal output.
2. A prototype of a 30 kWh REE-free/lean motor and levitation system for a flywheel for energy storage.
3. A prototype of a 200 kW REE-free-lean e-motor for EV. The prototypes for validation in each application will contain: »25 kg of magnetic powder for wind generator, 10-12 kg for the e-motor and 5 kg for the flywheel prototype.
4. A set of REE-free bonded magnets will be produced for automotive components application (at least 5 kg).

To integrate sustainability and social aspects in our solutions: We aim at reducing by 20%/80% the carbon footprint in the PMs sector by the substitution of REE magnets for REE-lean/free (respectively) materials with lower global warming impact. We will address circularity of our solutions by developing the recyclability of our magnets (reusing 15% of production wastes) and devices (via a Design for Recycling approach). Life Cycle Assessment (LCA) and socio-techno-economic analyses will be employed to assess the sustainability and social impact (assess whether additional mining in EU is necessary) of our technologies and will inform decisions on composition, production and manufacturing methods.

To maximize BEETHOVEN impact on EU autonomy, competitiveness and resilience. Through the design and implementation of Exploitation plans and Dissemination & Communication strategies, we aim at maximizing the expected impacts of BEETHOVEN to Europe´s autonomy and resilience. In particular, the ultimate project goal is to reduce REE imports by 2.2-4.9 ktons by 2033. We will devote efforts to developing and nurturing skills transfer activities related to magnet manufacturing and handling, with the aim of reaching at least 100 professionals and students.