Domestic Recovery of Gallium from Waste through Flash Electrothermal Chlorination

The Defense Logistics Agency SBIR topic DLA254-003 seeks modular, scalable technologies to convert U.S.-sourced materials into cost-competitive gallium compounds for military electronics. Flash Metals Texas, in partnership with the Tour Group at Rice University, proposes to develop a compact electrothermal chlorination system that can selectively recover gallium from domestic manufacturing waste. The system uses short, high-temperature pulses in a chlorine atmosphere to convert gallium into volatile gallium trichloride (GaCl?), which is then collected and analyzed.The project targets two underutilized but high-purity feedstocks: gallium paste from refinery operations, supplied by Indium Corporation, and gallium-containing electronic scrap, supplied by Dynamic Lifecycle Innovations. In Phase I, the team will perform thermodynamic studies, characterize feedstocks, optimize reactor parameters, and implement basic in situ monitoring tools. Flash Metals Texas will conduct chlorination trials using an existing scaled reactor platform, while the Tour Group will provide SEM-EDS, XRD, and ICP-MS characterization. A preliminary technoeconomic and life cycle analysis will be completed to assess feasibility relative to hydrometallurgical methods.Phase I will culminate in a demonstration of 90% product purity and 80% recovery yield, with data supporting readiness for pilot-scale operation in Phase II.