New Future for Rare Earths

Neodymium praseodymium oxide powder produced by MP Materials.

Oak Ridge National Laboratory (ORNL) has played a significant role in advancing the extraction of rare earths in the U.S. Rare earths, especially neodymium and praseodymium, are essential for powerful permanent magnets used in a wide array of industries. The U.S. and allied nations are increasingly concerned about China's dominance in the rare earth market, which produces about 90% of processed rare earths. In response, the U.S., Australia, and Canada are investing heavily in their own production capabilities to secure a stable supply chain.

However, the extraction process of rare earths is environmentally challenging. Traditional extraction methods are expensive and often yield poor results. The focus is shifting towards enhancing processing technologies to create a more competitive edge against Chinese operations, which boast a well-established network of separation plants.

This is where ORNL's contributions become crucial. ORNL has developed a new chemical extraction method that promises to decrease the use of solvents, water, and energy by up to 60%. The process minimizes the environmental impact associated with traditional methods that rely on harsh acidic solutions. This innovative approach not only enhances efficiency but also improves the selectivity of the extraction process, increasing the purity of the extracted rare earths.

Conventional extraction processes involve complex liquid-liquid separation techniques, which are both resource-intensive and generate significant waste. The new ORNL method allows for the recycling of acids without the need for additional chemicals. This streamlines the extraction process and addresses some of the environmental concerns that have historically plagued the rare earth industry.

Collaboration between ORNL and industry players, such as MP Materials, Mountain Pass, California, is pivotal for the commercialization of this new technology. As the demand for rare earths continues to grow, particularly in the context of green technologies and defense applications, the work being done at ORNL represents a critical step toward achieving a more sustainable and competitive rare earth supply chain. The innovative techniques being explored not only aim to enhance production efficiency but also to ensure that the U.S. and its allies can secure a reliable supply of these vital materials, ultimately supporting technological advancement and national security.