Novel Technique for Domestic Rare Earth Oxide Separation and Rare Earth Metal Reduction

China has strategically invested to control the entire supply chain of rare earth metals that are crucial for energy production technology like wind turbines, and for clean technology applications like electric vehicles. The US has no rare earth metallization capacity and has very limited separation capabilities, with no production scale facilities. High energy requirements, hazardous waste generation and the associated costs make traditional processes non-viable in a US setting. While recent efforts have increase US mining operations, this rare earth material still needs to be sent to China for separation and metallization. Phoenix Tailings has developed novel techniques to separate REOs without the use of hazardous chemicals and reduce them to REMs using 35-45% less energy. Upon extraction of rare earth concentrates from tailings or an ore source, PT will separate REOs through selective halogenation which decreases complexity and intensity as compared to conventional methods. The separated REOs are then reduced using a mixed halide molten salt which increases cell efficiency and decreases energy requirements. These techniques combine to form a new domestic rare earth supply chain, removing cost preventative energy requirements and environmentally unacceptable solvents from the process.