KEY POINTS
-
American Rare Earths has started small-scale continuous processing of ore from its Halleck Creek project in Wyoming.
-
The programme aims to produce neodymium and praseodymium oxide and metal for use in permanent magnets.
-
The company is exploring ways to strengthen US rare earth processing capacity and reduce dependence on overseas suppliers.
Australian-listed American Rare Earths has started small-scale continuous processing of ore from its Halleck Creek project in Wyoming, United States, as it advances plans to develop domestic rare earth processing capabilities.
The processing work is taking place at the research facility of Novex, a US-based metallurgy and metallisation company in Washington. The programme is designed to produce neodymium and praseodymium oxide before converting the materials into metal.
The testwork is being conducted by Wyoming Rare, a wholly owned subsidiary of American Rare Earths, as part of the Halleck Creek process verification and selected rare earth metal production demonstration programme.
The company said the initiative would improve its understanding of the metallurgical characteristics of ore from the Halleck Creek deposit while demonstrating the production of high-purity rare earth oxides and metals.
The current pilot operation is separate from a larger pilot plant that American Rare Earths plans to establish at the Saskatchewan Research Council in 2027.
Company targets production of magnet materials
A key objective of the programme is to advance the processing of rare earth materials beyond the oxide stage to produce metals that can be used by manufacturers.
American Rare Earths explained that magnet manufacturers cannot use separated rare earth oxides directly. The materials must first be converted into metals and alloys before they can be incorporated into permanent magnets.
This conversion process remains a significant bottleneck in the global rare earth supply chain, particularly outside China.
The company believes that developing the ability to process Halleck Creek ore into finished rare earth metals could help connect its Wyoming mineral resource to the United States’ growing midstream processing industry.
Neodymium and praseodymium are important materials used in high-performance permanent magnets, which are required in several industrial applications, including electric vehicles, wind turbines and other advanced technologies.
Partnership covers the full processing chain
Wyoming Rare has signed a memorandum of understanding with Novex to process material from Halleck Creek through a connected production circuit.
The proposed process will cover several stages, beginning with concentrate production and continuing through leaching, purification and separation before producing neodymium and praseodymium oxide and metal.
The arrangement is intended to provide a clearer understanding of how the different processing stages can work together to produce materials suitable for downstream manufacturing.
By working with Novex, American Rare Earths is seeking to demonstrate that material from its Wyoming project can be processed into higher-value products within the US supply chain.
Larger production campaign under consideration
American Rare Earths said it would assess the results of the current programme before deciding whether to proceed with a larger processing campaign with Novex.
The proposed expanded programme would target the production of a 200 g neodymium and praseodymium metal bar.
Achieving this target would require additional concentrate, alongside further separation and metallisation work.
The expanded campaign would also investigate the processing of other rare earth elements, including samarium, dysprosium and yttrium.
These additional materials could broaden the range of products the company may eventually be able to supply to manufacturers.
Halleck Creek project forms part of US supply ambitions
The Halleck Creek project is located in Wyoming, with the Cowboy State Mine designated as the first development phase of the broader project.
American Rare Earths is working to establish a processing pathway that links the project’s mineral resources with domestic US production of separated rare earth materials and metals.
The latest testwork represents an important step in assessing the technical processes required to achieve that objective. However, the company will need to evaluate the results before determining the scale and next stage of development.
The initiative comes amid efforts by the United States to strengthen its rare earth supply chain and reduce reliance on foreign processing capacity, particularly in the production of materials needed for advanced manufacturing and clean energy technologies.
