Complexity of rare earths transformation from mine to magnet

Complexity of rare earths transformation from mine to magnet

The Complex Process of Rare Earths: Unveiling the Journey to Green Energy Revolution

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Aug 2 (ANBLE) – MP Materials (MP.N) and other Western companies are seeking to develop supplies of processed rare earths needed for the green energy revolution in a sector dominated by China. The 17 silvery-white rare earth minerals are not uncommon in the earth’s crust. But deposits that are economically viable are more difficult to find, and the real rarity comes in the complex process to separate them into the materials needed to produce permanent magnets used in a range of critical products. China accounts for about 60% of global rare earth mine production, but its share jumps to 85%-90% of processed rare earths and magnet output. There are only five non-Chinese rare earth refineries in operation, construction, or re-commissioning, according to Goldman Sachs. Below are the complex steps that rare earths must take to end up as magnets used in electric vehicles and wind turbines – the two main areas driving demand in the coming years.

A Journey that Begins with Mining

Ore is the starting point for the production of rare earths. It is extracted from open pits or underground mines and then crushed. The ore, containing a small percentage of rare earths, undergoes flotation, magnetic or electrostatic processing to produce a mixed rare earth concentrate. This concentrate typically comprises 60% to 70% rare earth minerals. Some rare earth concentrates are produced as byproducts of mining waste or from other metals such as mineral sands or iron ore.

Confronting Radioactivity

Certain types of rare earth ore, like monazite, require an additional step to remove radioactive thorium or uranium. Acid is commonly used to eliminate these radioactive elements from the ore, ensuring the safety and purity of the final rare earth products.

The Delicate Art of Separation

Among the various steps involved in the production of rare earths, separation stands out as one of the most challenging and vital. Developed in U.S. government research laboratories post-World War II, separation involves isolating individual rare earth minerals from the mixed concentrate. The process relies on techniques such as ion-exchange and solvents like ammonia, hydrochloric acids, and sulphates. While effective, some of these chemicals produce toxic waste that poses health risks, including cancer. It is important to note that “light” and “heavy” rare earths require different separation circuits to extract the individual minerals. Although new, environmentally friendly separation technologies are being developed, their widespread adoption is yet to be seen.

From Precious Rare Earth Oxides to Metals and Alloys

Following the completion of separation, the rare earth oxides or carbonates are further refined into rare earth metals. The most commonly used permanent magnets combine rare earths neodymium and praseodymium with iron and boron, creating an alloy. This alloy is then placed in a vacuum induction furnace, where it undergoes a process of melting and fusion. To enhance the magnet’s heat resistance, small amounts of rare earths dysprosium and terbium are often added.

Crafting Magnets for Green Energy Revolution

To transform the rare earth alloy into practical products, the alloy ingots are broken down and jet-milled in an atmosphere of nitrogen and argon. This milling process reduces the alloy to micron-sized powder. The powder is then subjected to high temperatures and pressures through a process called “sintering.” Finally, the sintered powder is pressed into magnets, the heart of green energy revolution, finding application in electric vehicles and wind turbines.

In conclusion, while rare earth minerals may not be uncommon in the earth’s crust, the journey to transform them into magnets for the green energy revolution is arduous and complex. Western companies, such as MP Materials, are venturing to develop alternative supplies of processed rare earths to reduce dependence on China, which currently controls a significant majority of the global processed rare earth market. With China accounting for around 60% of rare earth mine production but a staggering 85%-90% of processed rare earths and magnet output, diversifying the refining capacity becomes crucial. As the demand for electric vehicles and wind turbines continues to grow, understanding the complex process from mining to magnet production provides valuable insights into the challenges and opportunities that lie ahead in the quest for a greener future.

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