Advanced Technology Development for Production of Rare Earth Metals

b. Advanced Technology Development for Production of Rare Earth Metals Approximately 40% of mined rare earth production is reduced to metals and alloys, including most of neodymium (Nd), samarium (Sm), and dysprosium (Dy), for applications such as neodymium metal for Nd-Fe-B permanent magnets, samarium metal for Sm-Co permanent magnets, lanthanum (La), cerium (Ce), praseodymium (Pr), and neodymium (Nd) for rechargeable battery electrodes [1]. A major issue for REE development in the United States is the lack of refining, alloying, and fabricating capacity that could process any future rare earth production [2]. The objective of the Advanced Technology Development for Production of Rare Earth Metals effort is to expand technology development beyond producing salable rare earth oxides (REO) from coal-based resources, ultimately producing rare earth metals (REMs) for use in intermediate and/or end product commercial and/or defense equipment through development of advanced metallization processing concepts. Current technology utilizes metallothermic high temperature reduction with very strong reductants such as lanthanum and calcium, or high temperature fused salt electrowinning whereby rare earths are dissolved in molten halide salt solutions and reduced by an external direct current power source. Details on the history and the many techniques for the reduction of rare earths compounds to metals can be found in Gupta and Krishnamurthy 2005 [3]. Applicants shall focus their proposals on: Development of advanced, novel, rare earth oxides/salts (REO/RES) to rare earth metals (REM) reduction techniques. Production and analytic characterization of small quantities of individually separated, high purity (ISHP) REM resulting from advanced, novel, REO-REM reduction processes. Conduct of preliminary techno-economic assessment (TEA). Preliminary design for process scale-up. Final Report addressing each of the bulleted items identified above. Questions Contact: Mark Render, mark.render@netl.doe.gov