- US targets processing bottleneck rather than searching for new rare earth deposits
- Parallel mining concept seeks profitability despite higher national and environmental labor costs
- Distributed processing model attempts to reduce reliance on single vulnerable mining sites
China is responsible for much of the world’s rare earth refining capacity, giving it control of supply chains in the event of trade disputes. This advantage was achieved by managing the expensive and complicated processing step on a large scale, often with lower costs and fewer environmental restrictions.
The United States has spent years trying to rebuild its rare earth supply chain, but mining alone has not solved the core problem. Transformation remains the sticking point, and as Data center dynamics reports, this is where the Defense Advanced Research Projects Agency is placing a high-risk bet.
Rare earth elements are not, as the name suggests, truly rare, and the United States already has access to large quantities of the ore. DARPA’s new Smash program is moving away from finding new deposits to focus on solving the processing bottleneck.
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Almost zero waste sorting
DARPA’s approach focuses on what it calls near-zero waste sorting on the periodic table. The goal is not just rare earth elements, but up to 80 stable elements that could be recovered from existing ore and waste streams.
“So the challenge is processing, not mining,” said Julian McMorrow, Smash lead and program manager in DARPA’s Microsystems Technology Office. “We want to develop technologies that will allow the industry to no longer waste more than 99% of its raw materials and to use all of these raw materials. »
Traditional mining wastes enormous amounts of materials during refining. More than two tons of ore and 13 tons of water can produce a single kilogram of copper, leaving most of the original material discarded.
Smash explores a parallel processing model that attempts to extract almost everything from a shovel of dirt at the same time. This concept borrows ideas from industries such as petroleum refining, where multiple outputs are effectively separated from a single input.
The program also reflects concerns about reliance on a single major site such as the Mountain Pass mine, which once dominated global rare earth production but struggled when refining costs became uncompetitive.
DARPA notes that concentrating production in one location creates vulnerability in the event of disruptions. A distributed model using diverse feedstocks, including mining waste and recycled materials, could reduce this exposure.
Smash will unfold as a 48-month effort divided into two phases. The first will focus on proof-of-concept experiments, while the second will move towards functional prototypes suitable for industrial mining environments.
Even if the technology succeeds in the lab, scaling it economically could prove tricky. Achieving profitability while maintaining high environmental and labor standards will be the real test.
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