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.
Techno-economic analysis (TEA) for rare earth processing
How TEA frames the economics of a processing route, methodology, cost drivers, and the metrics (NPV, IRR, OPEX, cash cost) that decide which routes get built.
Bubble–particle interaction: where flotation makes or breaks a project
The micro-physics of froth flotation, collision, attachment and detachment, and why ultrafine ores break conventional flotation cells in Stage 2 beneficiation.
What's proven, ultrasound & cavitation
17 studies · 36-field schemaA 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.
Paryani 2026
Phosphogypsum
Ultrasound added ~15.3% TREE leaching improvement
Organic-acid direction; still chemically assisted.
View sourceFontana et al. 2026
Secondary REE source
Demonstrates ultrasound-assisted REE recovery from secondary source
Needs full extraction for detailed conditions.
View sourceKhoshoei et al. 2026
Low-thorium monazite ore
>95% REE recovery (phosphate-free) vs <10% (untreated crude ore) in 10 minutes
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.
View sourceBrown et al. 2025
Diamond Creek, Idaho REE-rich soil
11.3-24.5x higher leaching rate than prior batch; yields 17.4% citric, 12.2% gluconic
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.
View sourceGuo et al. 2025
Coal gangue
85.65% Total-REE, 90.81% Light-REE, 68.46% Heavy-REE recovery
Newest addition; organic ammonium-salt leachate is a notably milder, less corrosive chemistry than mineral-acid routes used elsewhere in this database.
View sourceLütke et al. 2023
Phosphogypsum
84% (sonicated) vs. 68% (silent) under matched 0.6 M H₂SO₄, ~40-42°C, 20 min conditions
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.
View sourceChen et al. 2023
Coal fly ash
Optimal REY recovery condition reported
Acid-based, but useful for microwave thermal kinetics comparison.
View sourceGatiboni et al. 2020
Alkaline rock / carbonatite
Demonstrated ultrasound-assisted extraction/preparation route
Useful because it compares reactor styles, not only chemistry.
View sourceBehera et al. 2019
Waste NdFeB magnet
~99.99% Nd recovery at optimum ultrasound condition
Strong secondary-resource result; useful for process physics though not clay/ore.
View sourceYakaboylu et al. 2019
Coal fly ash
TREE leaching increased from 21.7% to 54.9-83.4%
Good evidence microwave preconditioning can unlock secondary REEs.
View sourceYin et al. 2018
Weathered crust ion-adsorption REE ore
75.5% total REE leaching
MgSO₄ can replace ammonium sulfate partly; ultrasound accelerates ion exchange.
View sourceDiehl et al. 2018
Carbonatite rock
Ultrasound increased REE extraction efficiency up to 35% over mechanical stirring
Suggests cavitation can help carbonatite/bastnäsite-type materials.
View sourceBurcher-Jones 2018 (Madagascar seawater clay trials)
Ion-adsorption clays
~40% recovery
Natural brine can leach, but much worse than ammonium sulfate.
View sourceVoßenkaul et al. 2015 (non-Chinese IAC)
Ion-adsorption clays
Recovery increased by ~20 percentage points to >90%
Acid improves recovery but lowers selectivity by dissolving Fe/Al/Si.
Chinese patent CN102639729B
Phosphogypsum
Claims improved REE recovery with lower acid and half treatment time
Patent-level evidence of hydroacoustic PG processing.
View sourceMoldoveanu & Papangelakis 2013 (ion-adsorption clay baseline)
Ion-adsorption clays
80-90% extraction reported
Baseline proves clays are primarily ion-exchange systems; not an ultrasound study itself, included as the conventional-process reference point.
View sourceBrown dissertation (unconfirmed)
Idaho REE-rich soil
Ultrasound improved rate; hybrid microwave + ultrasound explored to reduce reaction time/energy
Directly relevant to staged hybrid architecture.
View sourceState of the art across the value chain
6 stages · 20 solutionsThe 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 competePost-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 familiesResource & value chain
Beneficiation & upgrading
Recent process developments in beneficiation and metallurgy of rare earths: A review
Cheng et al. · Journal of Rare Earths · 2023
Up-to-date developments bridging beneficiation and metallurgy.
L8A review of the beneficiation of rare earth element bearing minerals
Jordens, Cheng & Waters · Minerals Engineering · 2013
Foundational survey of physical and surface-chemistry methods to upgrade REE ores before chemistry.
L1Leaching
Recent Progress on REE Extraction from Ion-Adsorption Clay Deposit: A Systematic Literature Review
Yudha et al. · Circular Economy & Sustainability · 2026
Current state of the art specifically for ion-adsorption clay, our deposit class of interest.
L2Application of Magnesium Sulfate in In-Situ Leaching of Rare Earth Elements
Pereira · Intl. Journal of Current Science Research & Review · 2026
Magnesium sulfate as a lower-pollution alternative leaching agent for clay deposits.
L6Development of leaching agents and mechanisms for REE leaching from ion adsorption clay
Ahmed, Maulud, Nawaz & Bustam · Sustainable Chemistry & Pharmacy · 2025
Mechanistic look at leaching-agent design to improve clay recovery beyond ammonium sulfate.
L4Review on the Development and Utilization of Ionic Rare Earth Ore
Luo et al. · Minerals (MDPI) · 2022
Open-access overview of ionic (clay) rare-earth ore mining and extraction practice.
L5Separation & refining
Design of Multi-Stage Solvent Extraction Process for Separation of REE
Mining (MDPI) · Mining (MDPI) · 2023
How industrial multi-stage SX circuits are dimensioned for clean REE splits.
L9Simulation of Solvent Extraction Circuits for the Separation of REE
Turgeon, Boulanger & Bazin · Minerals (MDPI) · 2023
Open-access simulation framework for designing and de-risking SX circuits.
L10Dynamic Modeling for the Separation of REE Using Solvent Extraction
Ind. & Eng. Chemistry Research · I&EC Research / OSTI · 2017
Predicts separation performance from lab equilibrium data, the link between bench and plant.
L11Process intensification
Process Intensification for Rare Earth Element Solvent Extraction Separations
Cross, Glatz & Parkinson · AIChE, Chemical Engineering Progress · 2026
Agitated extraction columns replacing mixer-settlers to cut capital cost and footprint.
L12Membrane Separation for Rare Earth Elements (A Review)
Ben-Elijah, Lutz-Rechtin, Wickramasinghe & Wang · Membranes (MDPI) · 2026
Current review of membrane routes as an emerging alternative/complement to SX.
L14Process intensification of element extraction using centrifugal contactors in the nuclear fuel cycle
Baker, Fells, Carrott et al. · Chemical Society Reviews · 2022
Centrifugal contactors deliver fast, compact continuous separation, directly relevant to continuous REE refining.
L13Rare Earth Elements Recovery Using Selective Membranes via Extraction and Rejection
Membranes (MDPI) · Membranes (MDPI) · 2022
Selective-membrane concepts for REE recovery and rejection.
L15Efficient enrichment and recovery of REE with low concentration by membrane dispersion micro-extractors
Separation & Purification Technology · Separation & Purification Technology · 2017
Micro-extractors intensify mass transfer for dilute REE streams.
L16This 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.