Library

A growing database of sourced solutions.

Every technology claim on this site links back to the published literature. This library is the running record, white papers, reviews and patents on rare earth processing, organised by where they sit in the value chain. It grows as we find and vet new sources.

Articles

Explainers we write to make the research authoritative and accessible, methodology, industry benchmarks and the economics behind the technology.

What's proven, ultrasound & cavitation

17 studies · 36-field schema

A living, sortable synthesis of the published evidence on ultrasound- and cavitation-assisted REE extraction, what each study actually demonstrated, on which feedstock, and how strong the evidence is. Every entry links to its source and carries an evidence tier so proven results are never conflated with early-stage claims.

Evidence
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Paryani 2026

Phosphogypsum

Tier 3

Ultrasound added ~15.3% TREE leaching improvement

Ultrasound + citric acid· 2 M citric acid· 120 min

Organic-acid direction; still chemically assisted.

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Fontana et al. 2026

Secondary REE source

Tier 1

Demonstrates ultrasound-assisted REE recovery from secondary source

Sustainable ultrasound-assisted extraction and recovery

Needs full extraction for detailed conditions.

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Khoshoei et al. 2026

Low-thorium monazite ore

Tier 1

>95% REE recovery (phosphate-free) vs <10% (untreated crude ore) in 10 minutes

Mechanochemical dephosphorization + ultrasound-intensified leaching· HNO₃· 10 min

First study in this database to target monazite directly; demonstrates that the bottleneck for refractory phosphate ores is phosphate removal, not the leaching step itself, once ultrasound is added.

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Brown et al. 2025

Diamond Creek, Idaho REE-rich soil

Tier 1

11.3-24.5x higher leaching rate than prior batch; yields 17.4% citric, 12.2% gluconic

Continuous ultrasound-assisted organic-acid leaching· Citric acid or gluconic acid· 1-3 h continuous runs (55 min on / 5 min cooling cycle)

Most important continuous-process paper; energy/reagent costs remain limiting. Diamond Creek soil, LSP-500 horn, 4000 mL reservoir, and duty-cycle details confirm this is a genuine continuous-flow architecture, not a scaled-up batch run.

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Guo et al. 2025

Coal gangue

Tier 1

85.65% Total-REE, 90.81% Light-REE, 68.46% Heavy-REE recovery

Ultrasound-assisted leaching with betaine hydrochloride· Betaine hydrochloride

Newest addition; organic ammonium-salt leachate is a notably milder, less corrosive chemistry than mineral-acid routes used elsewhere in this database.

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Lütke et al. 2023

Phosphogypsum

Tier 1

84% (sonicated) vs. 68% (silent) under matched 0.6 M H₂SO₄, ~40-42°C, 20 min conditions

Ultrasonic probe + acid leach· 0.6 M H₂SO₄· 20 min

A 16-percentage-point absolute improvement (≈24% relative improvement) attributable to acoustic cavitation, microjet-induced cracking, particle-size reduction, and enhanced convective transport, not simply '~20% higher,' which understates the relative gain and omits the absolute baseline.

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Chen et al. 2023

Coal fly ash

Tier 1

Optimal REY recovery condition reported

Microwave-assisted HCl leaching· 3 M HCl· 30 min

Acid-based, but useful for microwave thermal kinetics comparison.

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Gatiboni et al. 2020

Alkaline rock / carbonatite

Tier 1

Demonstrated ultrasound-assisted extraction/preparation route

Ultrasound-assisted sample preparation; bath, cup horn, probe compared

Useful because it compares reactor styles, not only chemistry.

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Behera et al. 2019

Waste NdFeB magnet

Tier 1

~99.99% Nd recovery at optimum ultrasound condition

Ultrasound-assisted acetic acid leach; microwave pretreatment comparison· 0.4 M acetic acid· 120 min

Strong secondary-resource result; useful for process physics though not clay/ore.

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Yakaboylu et al. 2019

Coal fly ash

Tier 1

TREE leaching increased from 21.7% to 54.9-83.4%

Microwave pretreatment before leaching· Acid leach after pretreatment

Good evidence microwave preconditioning can unlock secondary REEs.

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Yin et al. 2018

Weathered crust ion-adsorption REE ore

Tier 1

75.5% total REE leaching

Ultrasound-assisted salt leach· 3 wt.% MgSO₄· 30 min

MgSO₄ can replace ammonium sulfate partly; ultrasound accelerates ion exchange.

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Diehl et al. 2018

Carbonatite rock

Tier 1

Ultrasound increased REE extraction efficiency up to 35% over mechanical stirring

Ultrasound-assisted extraction

Suggests cavitation can help carbonatite/bastnäsite-type materials.

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Burcher-Jones 2018 (Madagascar seawater clay trials)

Ion-adsorption clays

Tier 3

~40% recovery

Seawater leach· Seawater ions

Natural brine can leach, but much worse than ammonium sulfate.

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Voßenkaul et al. 2015 (non-Chinese IAC)

Ion-adsorption clays

Tier 2

Recovery increased by ~20 percentage points to >90%

Salt + mild acid leach· 0.5 M ammonium sulfate + 0.1 M H₂SO₄

Acid improves recovery but lowers selectivity by dissolving Fe/Al/Si.

Chinese patent CN102639729B

Phosphogypsum

Tier 4

Claims improved REE recovery with lower acid and half treatment time

Hydroacoustic action + mixed acid + ion exchange filter· 1-3 wt.% H₂SO₄/HNO₃ mixture, ratio 3.2-1.2· 8-12 min

Patent-level evidence of hydroacoustic PG processing.

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Moldoveanu & Papangelakis 2013 (ion-adsorption clay baseline)

Ion-adsorption clays

Tier 1

80-90% extraction reported

Conventional ammonium sulfate salt leach (non-ultrasonic baseline)· (NH₄)₂SO₄· ~10 min equilibrium

Baseline proves clays are primarily ion-exchange systems; not an ultrasound study itself, included as the conventional-process reference point.

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Brown dissertation (unconfirmed)

Idaho REE-rich soil

Unconfirmed

Ultrasound improved rate; hybrid microwave + ultrasound explored to reduce reaction time/energy

Batch ultrasound -> continuous ultrasound -> microwave + ultrasound· Organic acids, especially citric / gluconic

Directly relevant to staged hybrid architecture.

View source

State of the art across the value chain

6 stages · 20 solutions

The benchmark we measure ourselves against. This is the leading edge the industry is moving toward at every step, from mining to magnet recycling. Our continuous separation method operates in Stage 2, beneficiation, right after grinding and washing, so that stage is where we compete directly.

Stage 1 · Mining & extraction

Moving away from high-pollution in-situ chemistry toward biodegradable, electrically driven and biological recovery.

Bio-leaching / organic-acid leaching

Biodegradable organic acids (citric, ascorbic, oxalic) replace toxic ammonium sulfate in ionic clays, eliminating groundwater nitrogen pollution.

Displaces: Ammonium-sulfate in-situ leaching

Electrokinetic mining (EKM)

A low-voltage electrical field applied directly into clay beds migrates REE ions toward recovery wells, cutting chemical reagent use by up to 80%.

Displaces: Reagent-intensive heap / in-situ leaching

Autonomous & electrified fleets

AI-optimised all-electric trucks and drills paired with hyperspectral core scanning surgically map and mine high-grade zones in open pits.

Displaces: Diesel fleets and bulk mining

Phytomining

Hyperaccumulator plants draw REEs from low-grade soils or legacy tailings through their roots; the biomass is harvested and burned to a high-grade bio-ore.

Displaces: Leaving low-grade soils and tailings unmined

Stage 2 · Beneficiation & pre-treatment

Where we compete

Post-grinding and washing, where our method operates. The race is to upgrade feedstock with less chemistry, finer selectivity and continuous throughput.

AI-driven machine-vision flotation

High-speed cameras and ML analyse froth bubble size, velocity and colour to micro-adjust chemical dosing in real time.

Displaces: Manual / fixed-dose froth flotation

Superconducting WHIMS (S-WHIMS)

Liquid-helium-cooled superconducting magnets generate >2 Tesla fields to capture microscopic, weakly paramagnetic REE grains from washed slurries.

Displaces: Conventional WHIMS magnets

Continuous centrifugal concentrators (Falcon / Knelson)

Fluidised gravity bowls spinning above 100 G separate heavy REE minerals from light silicate sand with no chemical reagents.

Displaces: Reagent-dependent flotation circuits

Selective flocculation

Smart polymers bind only the surfaces of REE minerals in a washed slurry, clumping and settling them, bypassing bubble flotation entirely.

Displaces: Traditional froth flotation

Stage 3 · Acid cracking & hydrometallurgy

Replacing fossil-fuel roasting kilns with room-temperature, pressurised and targeted-energy chemistry.

Mechanochemical activation

High-energy ball mills force reactions between concentrates and reagents at room temperature, eliminating 500°C roasting kilns.

Displaces: Sulfuric-acid bake roasting

Alkaline autoclave leaching

Closed-loop high-pressure sodium-hydroxide vessels digest monazite/bastnäsite at lower temperatures while safely isolating thorium and uranium upfront.

Displaces: Open acid-bake cracking

Microwave-assisted roasting

Targeted microwave energy heats only the REE mineral grains within a concentrate, cutting overall energy use by up to 50%.

Displaces: Conventional rotary-kiln roasting

Stage 4 · Separation (elemental isolation)

Shrinking and de-toxifying the hardest step, splitting the 17 chemically near-identical elements.

Continuous chromatography (centrifugal / true moving bed)

Solid-phase resin columns replace giant liquid-liquid SX mixer lines, separating the elements with a ~90% smaller footprint.

Displaces: Multi-stage solvent extraction

Biosorption & engineered proteins

Synthetic-biology proteins such as lanmodulin bind, sort and separate specific REEs from solution with ultra-high affinity.

Displaces: Organophosphorus solvent extractants

Ionic liquids

Custom non-volatile, non-flammable organic salts selectively extract heavy REEs at room temperature, replacing toxic kerosene diluents.

Displaces: Kerosene-diluent solvent extraction

Stage 5 · Metallization (reduction)

Decarbonising and lowering the energy footprint of turning oxides into pure metal.

Inert-anode molten-salt electrolysis

Non-consumable ceramic/cermet anodes in fluoride baths release pure oxygen instead of CO₂, eliminating carbon emissions from reduction.

Displaces: Carbon-anode molten-salt electrolysis

Metal-vapour vacuum reduction

Heating oxides with a reducing metal under ultra-high vacuum lets pure REE metal vaporise and condense cleanly, skipping salt baths.

Displaces: Metallothermic salt-bath reduction

Ionic-liquid electrowinning

Deposits pure REE metals from ionic-liquid solutions below 100°C, slashing the energy footprint of 1,000°C molten-salt infrastructure.

Displaces: High-temperature molten-salt electrowinning

Stage 6 · Magnet manufacturing & recycling

Using less heavy REE, cutting machining waste, and recovering material without acid waste streams.

Grain-boundary diffusion (GBD)

Heavy REEs (Dy, Tb) are sprayed onto a magnet surface and baked so atoms seep only into grain borders where heat resistance is needed, using far less heavy REE.

Displaces: Bulk heavy-REE alloying

Additive manufacturing of magnets

Laser powder-bed fusion or binder jetting prints magnets in final geometry, dropping machining waste from 60%+ toward zero.

Displaces: Sinter-and-machine magnet production

Acid-free chemical recycling (copper salts)

Copper nitrate/acetate solutions dissolve REEs out of swarf and end-of-life electronics at 99.5%+ purity without acid-dump lines.

Displaces: Strong-acid hydrometallurgical recycling

White-paper sources

15 entries · 5 technology families

This is a living reference. As new white papers, pilot results and patents are reviewed, they are added here and linked from the relevant technology entries. Send a paper to add it to the queue.