Highlights

• Rice University researchers developed a revolutionary one-step method to recover rare earth elements using flash Joule heating.
• The method achieves over 90% yield with 87% lower energy consumption.
• It vaporizes non-rare earth metals using high-temperature chlorine gas, leaving purified rare earth element residues in seconds.
• The innovation supports U.S. national efforts to secure critical mineral supply chains.
• The method reduces environmental damage from traditional recycling processes.

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A research team led by James Tour, PhD, T.T. (opens in a new tab) and W.F. Chao Professor of Chemistry at Rice University, has unveiled a breakthrough method to recover rare earth elements (REEs) from discarded magnets using flash Joule heating (FJH) with chlorine gas. The study, published in the Proceedings of the National Academy of Sciences (PNAS), demonstrates a one-step, seconds-long recovery process with major environmental and economic advantages compared to conventional recycling.

Study Summary and Findings

First author Shichen Xu, PhD, (opens in a new tab) a Rice postdoctoral researcher, and colleagues hypothesized that by rapidly heating magnet waste to thousands of degrees Celsius in milliseconds under a chlorine atmosphere, volatile non-REE chlorides such as iron and cobalt would vaporize first—leaving purified REE residues behind.

Testing on neodymium-iron-boron and samarium-cobalt magnets confirmed the hypothesis. Results included:

• >90% REE yield and purity in one step
• 87% lower energy consumption, 84% fewer greenhouse gas emissions, and 54% reduced operating costs versus hydrometallurgy
• Elimination of water and acid inputs, addressing one of the most polluting steps in traditional recycling

A life-cycle assessment and techno-economic analysis confirmed the method’s potential viability at scale. The intellectual property has already been licensed to Flash Metals USA, (opens in a new tab) which plans commercial operations by Q1 2026.  Flash Metals USA is a subsidiary to Metallium Ltd.

Metallium Ltd, formerly MTM Critical Metals Ltd, is an Australian public company focused on both traditional mineral exploration and the development of sustainable metal recovery technology. The company holds a strategic portfolio of exploration assets in Western Australia and Québec, Canada, which are prospective for rare earth elements (REE), niobium, gold, and other critical minerals. Crucially, Metallium has shifted its core strategy toward its proprietary FJH technology, licensed from Rice University as Rare Earth Exchanges (REEx) reports herein.

This low-carbon, high-efficiency electro-thermal process allows for the recovery of valuable metals from waste streams like e-waste and battery black mass, as well as from ores, without the use of harsh acids or smelting. With a new U.S.-focused rollout, Metallium is constructing its first commercial FJH plant in Texas and has secured contracts, including a Phase 1 agreement with the U.S. Department of Defense to recover gallium.

Implications

This innovation supports U.S. national efforts to secure critical mineral supply chains while reducing environmental damage from legacy processes. Modular FJH units could be deployed near e-waste collection hubs, cutting transport costs and decentralizing REE recovery. The approach offers a path toward a circular rare-earth economy, helping to reduce dependence on foreign mining and refining.

For investors and policymakers, the findings highlight a credible alternative to China-dominated REE processing, aligning with Department of Defense and Department of Energy priorities for supply-chain resilience.

Limitations

Despite its promise, the study remains at a laboratory-to-pilot stage. Key questions include:

• Scale-up feasibility: Can ultrafast FJH reactors operate safely and reliably at industrial throughput?
• Chlorine handling risks: While cleaner than acid leaching, chlorine gas presents logistical and safety challenges.
• Residue management: The fate of vaporized by-products (iron, cobalt chlorides) requires careful downstream capture and utilization.
• Economic competitiveness: Commercial proof will depend on integration with existing recycling streams and market acceptance of recovered REEs.

Conclusion

Rice University’s flash Joule heating breakthrough offers a glimpse of a future where REEs are recycled at low cost, low environmental impact, and high efficiency. If scaled, this process could transform how nations manage electronic waste and critical mineral security. But scaling, safety, and market dynamics remain critical hurdles before this technology can anchor a truly circular REE economy.

Citation: Xu, S., Tour, J.M., et al. “Rapid flash Joule heating enables selective recovery of rare earth elements from electronic waste.” Proceedings of the National Academy of Sciences (PNAS), Sept. 29, 2025.

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