Rare Earth Metals Recycling by Hydrogen Reduction of REOs/Salts

C51-27a-271194Rare earth elements (REEs) are crucial to the production of green energy motors in wind turbines, hybrid cars, electric vehicles, and electronic devices. REEs are also widely used in defense systems, including precision-guided munitions, radar systems, avionics, night vision equipment, satellites and guided missiles. China dominates the REEs production and exports and is continuing to reduce REEs exports. DoD and DOE are looking options to increase domestic production in the U.S. However, rebuilding the U.S. rare earth industry could take many years. In our DOE SBIR Phase 1 project, we have successfully completed the proof-of-concept of recycling rare earth metals using the three processes. In this DOE SBIR Phase 2 project, we will recycle rare earth metals from post-consumer products and waste catalysts. Of the five critical REEs, [dysprosium (Dy,66), neodymium (Nd,60), terbium (Tb,65), europium (Eu,63), and yttrium (Y,39)], we will target on Dy, Nd, Eu, Y, and also Sm, Ce, two other popularly used REMs. This project will scale up the processes and lead to commercialization of the REMAGNET and THERMINE processes at the end of the project, and a modular plant design to produce commercial quantities of rare earth metals (REMs) with the H2REMs process. A techno-economic assessment (TEA) will be performed to provide a return of investment estimate for the REMs recycling business.