Hightlights
- Scientists are developing cleaner methods for rare-earth element extraction with grants like DOE’s award to Lydia Kisley.
- China dominates the rare-earth market, but global competition is growing.
- Emerging technologies aim to make extraction processes more efficient and environmentally friendly.
A messy, expensive, and environmentally troubling process goes into the separation of key rare earth elements from various mineral ores or recycled materials. The removal of rare-earth elements, or REEs, involves a process ranging from the extraction of terbium to lithium and involves soaking chemical compounds in vats of kerosene to separate the atoms. Generally, the United States leans on other nations to extract rare-earth elements due to a host of environmental-related considerations. But this could change with breakthroughs, and the present period in history is likely to have many of them.
Recently, scientists at Case Western Reserve University (opens in a new tab) hope to completely upend the process of refining these minerals, which are necessary in hundreds of high-tech applications, including cell phones, computer hard drives, and medications. Lydia Kisley leads the way with a recent grant award from the Department of Energy (DOE).
The assistant professor of physics at the university’s College of Arts and Sciences secured the five-year, $875,000 Early Career Award (opens in a new tab), seeking to understand the process of separating and extracting rare-earth elements—essential for green technologies. Key to this process will be the imaging efficient and environmentally sustainable separation technologies that are under development. The grant involves Kisley and her collaboration with a pair of scientists.
As a contribution to this research, the Kisley Lab (opens in a new tab) will develop a new, groundbreaking microscope, which would provide new details obscured in traditional methods, as reported by the university’s online news (opens in a new tab).
“We will be able to see the atoms binding at surfaces designed to capture these REEs as they’re happening in real-time,” Kisley said. “Think of it as a colander capturing metal ions. We will be able to see what’s happening.” Rare-earth elements observed in the process of separation under a specialized microscope.
According to the DOE grant announcement, Kisley’s work could “dramatically reduce the environmental costs of REE extraction, offering a more sustainable approach to support clean energy infrastructure. This award is a significant recognition of Dr. Kisley’s contributions to the field of physics and her leadership in advancing sustainable technologies.”
The process of removing REEs from their host ore is complex and involves several stages, including mining, concentration, separation, and refining. These steps are technically demanding and often environmentally challenging. Here’s a breakdown of the general process and countries involved:
In mining and extraction, REEs are extracted from mineral deposits, such as bastnaesite (in China and the USA), monazite (in Australia and Brazil), and xenotime. The mining process is relatively standard, but REEs are found in small concentrations, making the mining costly and environmentally impactful. Countries involved in mining include China, Australia, the USA, Russia, India, Myanmar, and Brazil. China has been dominant, but this is changing and fast.
After mining, the ore is crushed and ground into fine particles to liberate the REE-bearing minerals. These particles are then processed to concentrate the REEs.
Concentration methods, such as gravity separation, magnetic separation, and flotation, are used to separate the REE-bearing minerals from the host rock. The resulting concentrate contains higher percentages of rare earth oxides (REOs) but still needs further refining.
Chemical separation methods involve chemical leaching or acid treatment to dissolve the REEs from the concentrate. This process varies depending on the mineral type. The common method for bastnaesite involves roasting and then treating with acids like hydrochloric acid. For monazite, the concentrate is treated with sulfuric acid to separate thorium, uranium, and REEs, producing a solution containing a mixture of REE ions, which then undergo further separation.
In solvent extraction, a complex process is used to separate individual rare-earth elements. REEs are chemically similar, making it difficult to isolate them. Solvent extraction uses a series of liquid-liquid extractions to selectively extract individual REEs from the mixture. Countries involved in this stage include China, Malaysia, India, and Australia.
The purified rare earth oxides or salts are then processed into metals or alloys for industrial use. The refining process requires significant expertise and infrastructure. China dominates this phase, holding a large portion of global refining capacity, although Rare Earth Exchanges anticipates more competition.
Countries like China, Australia, and the USA dominate the rare-earth element supply chain. China controls about 85-90% of global production and processing, holding the largest reserves and most advanced refining capabilities.
Australia has major deposits like Mount Weld (opens in a new tab) and is increasing its mining and processing capacity. Companies like Lynas Rare Earths (opens in a new tab) play significant roles. The USA is rising with activities tracked by Rare Earth Exchanges.
The Mountain Pass mine (opens in a new tab) in California is a significant source of REEs, but much of its concentrate is sent to China for refining due to limited domestic processing capabilities. Again, monitor Rare Earth Exchanges for unfolding trends leading to greater competitive dynamics.
Malaysia processes rare earths, particularly in partnership with Lynas for refining materials extracted in Australia.
India and Brazil have REE reserves and some mining and processing capabilities, remaining smaller players compared to China and Australia.
The process of extracting and refining REEs is environmentally damaging, involving toxic chemicals and producing radioactive byproducts (especially when thorium or uranium is present). Environmental regulations and the high cost of processing outside of China are key challenges for other countries trying to compete in this space. This is why Rare Earth Exchanges monitors scientific trends, including research grants such as the one announced for Lydia Kisley at Case Western Reserve.
Future trends in rare earth extraction focus on investing in domestic supply chains in the USA, Australia, and the European Union to reduce reliance on China. New technologies are being explored to make the extraction process more efficient and less harmful to the environment.
In summary, rare earth extraction involves a series of highly technical and environmentally sensitive steps, with China predominating both mining and refining. Meanwhile, countries like Australia and the USA are working to increase their role in the global supply chain, and technological innovation will be a key enabler.
Daniel
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