Adi Mussin
Colorado School of Mines

Mechanochemical Extraction of Lithium from Spodumene: Scale-Up of the MELLT Process

This work advances the mechanochemical extraction of lithium from α-spodumene using the MELLT process. We optimized reagent selection, milling conditions, and scale-up performance from gram-scale to multi-kilogram batches. Initial scale-up revealed that low-energy milling was the primary limitation, with extraction yields of only 1–2%. After systematic adjustments to milling media, speed, and time, yields increased to 35–41% at the 0.7–1 kg scale. A major breakthrough came with identifying specific reagent as a high-performance solid leaching agent, achieving ~97% lithium extraction at lab scale with significantly reduced milling energy. Applying this to larger batches resulted in 46% extraction at 1 kg. With the upgraded mill at Mines, further optimization raised yields up to 83% for 0.5 kg and ~78% for 2 kg, demonstrating continuous improvement in mechanochemical efficiency and confirming the scalability of the MELLT methodology. These results show that MELLT can approach high extraction efficiency while reducing chemical inputs.

Anirudha Karati
Ames National Laboratory

Energy-efficient metallothermic reduction of rare earths

We demonstrate a scalable method to synthesize low-melting rare earth fluorides at room temperature using wet chemical techniques, without employing corrosive chemicals. Metallothermic reduction of this rare earth fluoride yields rare earth metal, which is then used to produce Nd-Fe-B-based permanent magnets (PMs). Traditionally, REEs are obtained via molten salt electrolysis or metallothermic reduction of RE salts. However, the lack of environmentally benign processes (i.e., those avoiding HF) for fabricating dry RE-fluorides remains a bottleneck in the REE processing industry.

Cong Trinh Truong
University of Pittsburgh

AI-Accelerated Evaluation of Alternative Magnet Materials for Permanent-Magnet Motor Design

The growing supply-chain risk of Nd-Fe-B magnets, essential to EVs, wind turbines, and defense systems, is accelerating efforts to develop less-critical substitutes. A major challenge in evaluating alternative magnets is the high computational cost of iterative FEA required for PM motor design. This study presents an AI-driven framework that accelerates motor design and material substitution assessments. Under Project FA-2.1.3, we evaluate the feasibility of less-critical CMI magnets (Sm-Fe-N, Project FA-2.2.5) as a substitute for Nd-Fe-B in e-bike motors through system-level modeling and rapid prototyping. We generate a diverse design dataset spanning motor geometries, magnet materials, operating conditions, and FEA performance outputs, which is then used to train a deep-learning model capable of rapidly predicting motor metrics and producing feasible designs in near real time. This approach eliminates the need for exhaustive simulation loops during early-stage design, providing substantial computational savings and enabling fast evaluation of alternative magnet materials.

Dex Altavilla
Pacific Northwest National Laboratory

Rare Earth Element (REE) Separation from Monazite using 3D Printed Centrifugal Contactors

REE separation is a crucial step in expanding the domestic supply of critical materials. The goal is to achieve selective separation of individual or adjacent pairs of REE from monazite feed. We investigate a multi-ligand solvent extraction system to partition REE into the organic solvent consisting of DGA-6 and a primary alcohol modifier in a paraffin diluent. The REE are selectively stripped from the loaded organic solvent by manipulating the salt and aqueous chelator (DOODA) concentrations in the aqueous strip solutions. Currently we use a 3D-printed centrifugal contactors to implement this solvent extraction system under countercurrent conditions. We optimized contactor performance for the separation of organic solvent and aqueous salt solution phases at various rotor speeds, O:A ratios, and total throughput volumes. The top parameters were used for the separation of REE from a monazite feed-HCl aqueous solution with the proposed DGA-based organic solvent in the extraction, scrub, and strip steps. We also investigate the replacement of the alcohol solvent modifier with weakly acidic HEH[EHP] to improve the selectivity profile. Our latest results will be presented.

Ernest Konadu-Yiadom
Colorado School of Mines

APPLICATION OF PHOSPHONIC-ACID LIGANDS FOR MONAZITE FLOTATION

A highly efficient flotation process is the preferred method for monazite recovery. This process utilizes the difference in surface hydrophobicity between valuable minerals and gangue minerals to separate them. Collectors such as phosphonic acids, fatty acids and hydroxamic acids are necessary to increase the surface hydrophobicity of valuable minerals and reduce the difference between the surface hydrophobicity of valuable and gangue minerals.

Godwin Akotenvusi Agbanga
Arizona State University

Thermodynamic Stability of Rare Earth Carbonates

Rare earth elements (REEs) are strategic materials important for technology, modern electronics, and energy. However, unstable supply chains have intensified global demand. A promising alternative source of REEs is recycled waste sludges generated during aluminum production. To understand and model fractionation and mobility of REEs and to improve extraction processes, it is essential to develop robust thermodynamic models of REE-H2O-CO2 interactions. This requires reliable thermodynamic data on rare earth carbonates.

Harshida Parmar
Ames National Laboratory

High coercivity Ce-Nd-Fe-B Nanoparticle

NdFeB permanent magnets are the strongest magnets and are widely used in many applications. Nevertheless, their growing demands lead to strain on the supply of rare earth elements, including Nd, Pr, Dy and Tb. Hence, Ce can be applied to produce magnetic materials. Also, it is much less utilized coproduct of Pr/Nd mining. However, Ce-Fe-B has far inferior intrinsic magnetic properties than Nd-Fe-B. It was shown theoretically that Ce-Fe-B magnetic property can be improved by partial replacement of Ce by Nd or Pr. Additionally, the calculation reveals that the magnetic property is enhanced in nanoscale particles. Conventional sintering techniques are unable to achieve the nanostructure in Ce-Fe-B. In this work, we have reported the magnetic properties of Ce-Nd-Fe-B nanoparticles prepared using a reduction diffusion approach. We have successfully prepared a series of Ce-Nd-Fe-B nanoparticles at various reduction-diffusion temperatures. Maximum coercivity 14kOe was achieved for 10 wt.% added Ce-Fe-B sample, while Ce-Fe-B sample has achieved 8.8kOe maximum coercivity.

Hur Abbas
University of Texas at Arlington

Core–Shell Engineering of Fe5C2@Fe3O4 Nanocrystals to Improve Magnetic Hardness

In this work, we investigate Fe5C2@Fe3O4 core–shell nanocrystals and demonstrate that the controlled formation of an Fe3O4 shell on Fe5C2 cores provides a beneficial route to enhance exchange anisotropy and overall magnetic hardness. The magnetite (Fe3O4) shell is produced via controlled oxidation, enabling tunable shell thicknesses below 5 nm. Structural and magnetic measurements confirm the successful formation of a ferrimagnetic Fe3O4 shell on a ferromagnetic Fe5C2 core, revealing a systematic increase in coercivity (~ 60%) with increasing shell thickness. This enhancement originates from interfacial exchange coupling between the Fe5C2 core and Fe3O4 shell, which stabilizes spin alignment. The Fe3O4 shell growth also suppresses interparticle dipolar interactions, leading to an increase in coercivity. The improvement in coercivity and anisotropy demonstrates a clear pathway for optimizing hard magnet performance in core–shell architectures. These findings underscore the effectiveness of nanoscale shell engineering as a strategy to tailor exchange anisotropy and advance the design of next-generation hard magnetic nanomaterials.

Jiapei Zhang Zhang
Purdue

Project 4.3.4: LCA, TEA and DOE for CMI Technologies

Our research integrates environmental and economic assessments of technologies (e.g., products, processes, and systems) to accelerate technology development. Using parameter-driven methods such as material flow analysis (MFA), life cycle assessment (LCA), techno-economic assessment (TEA), design of experiments (DOE), data analytics, and machine learning, we provide decision-support tools that advance collaborators’ technology readiness. Through collaborations with other CMI teams, we address challenges in energy technology and strengthen supply chain for critical materials like rare earth elements, lithium, and cobalt. Each method has a specific purpose. MFA systematically evaluates material and energy flows. LCA identifies environmental hotspots of product’s life cycle. TEA combines cost modeling with financial analysis to guide R&D decisions. DOE identifies key variables early in development process, characterizes effects parameters, and optimize process performance. Together, these approaches support economically viable technologies with minimal environmental impact. This poster presents recent collaborations and summarizes our contributions to Critical Materials Innovation Hub.

Kaustubh Mungale
Oak Ridge National Laboratory

Review of Platinum group metal recovery from US sources

U.S. platinum-group metals (PGMs) production remains modest relative to domestic demand but strategically important for automotive emissions control, chemical processing, and emerging hydrogen applications. This poster presents case studies of current operations of Sibanye-Stillwater’s Stillwater–East Boulder (MT) and by-product recovery linked to the Eagle Mine (MI), as well as prospective projects. Contextual statistics highlight scale and reliance: in 2024, world mine output was approximately 190,000 kg palladium and 170,000 kg platinum; U.S. mine production accounted for roughly 8,000 kg Pd (~4%) and 2,000 kg Pt (~1%), leaving the United States ~36% import reliant for palladium and ~85% import-reliant for platinum on an apparent consumption basis. Recycling statistics show approximately 120,000 kg of palladium and platinum were recovered globally from scrap in 2024, including about 45,000 kg Pd and 8,500 kg Pt from U.S. automobile catalytic converters, evidence that domestic secondary supply already plays an outsized role.

Konrad Burkmann
Arizona State University

Thermochemistry of Rare Earth Metals and Oxides to Describe the Thermodynamics of REE Systems

Rare earth element (REE) oxides are common intermediates and precursors in the production other rare earth compounds significant to industry and geology, such as rare earth carbonates and oxyphosphates. Reliable thermodynamic data are necessary to describe the formation and stability conditions of such compounds in that context. This fundamental thermodynamic information is typically obtained through calorimetry, and its accuracy is contingent on reliable reference data for the REEs in their metallic or simple oxide forms. However, it should be noted that published reference values vary significantly, and experimental issues such as the hygroscopic nature of REE sesquioxides or the partial oxidation of the metals are frequently overlooked.

Lauren Ward
Idaho National Laboratory

Understanding High Activity Salt Behavior with Various Organic Solvents

Lanthanides are often present in very low concentrations requiring processes that can recover from very low concentrations. How lanthanides salts interact with small polar organic molecules, via solvent driven fractional crystallization, could offer a path to high recoveries and separation of lanthanides. However, high activity salts can interfere with recovery of lanthanide salts. In this work, we look to better understand how high activity salts influence low activity salts in their separation capabilities to help achieve greater selectivity and separation during dimethyl ether-driven fractional crystallization. The impact of structural representative solvents on high activity salts and proxies for lanthanides was tested at various relative concentrations to organic to aqueous. Determining how mixed salts systems impact separations is essential to deploying fractional crystallization with dimethyl ether.

Luis Sánchez-Calderón
Missouri S&T

Recovery of Platinum Group Metals and Gold from Vacuum-Distilled Selenium Residues

Vacuum distillation (VD) of crude selenium (a copper refining byproduct) effectively removes volatile selenium and tellurium, leaving a residue rich in platinum group metals (PGMs) and gold. This study evaluates a sequential hydrometallurgical process for recovering PGMs and gold from VD residue (VDR). Characterization identified sodium sulfate as the primary gangue phase of the VDR. Water leaching at 32.0 ± 2 °C exploited the maximum solubility of Na₂SO₄ to produce a sulfate-free concentrate enriched in PGMs and gold. The sulfate-free residue was then leached in aqua regia to solubilize PGMs and gold. At 50°C, dissolution kinetics were rapid, achieving over 75% PGMs extraction within 2 hours. These findings demonstrate the technical feasibility of valorizing selenium-depleted residues as a secondary source of critical and precious metals.

Maja Wlodarczyk
Rutgers

Measurement and Modeling of Critical Materials Process Thermodynamics

Many of the most important problems in critical materials processing, especially extraction and separation of crucial elements, involve complicated phase equilibria. This can make process analysis and optimization a difficult task. Predictive modeling can both optimize existing processes and greatly reduce the time and number of experiments needed to identify key variables and ideal conditions for novel processes. CMI focus area 4.1.5 identifies understudied compounds relevant to these processes, measures thermodynamic properties, and integrates the results into modeling software which is used to provide solutions to problems encountered by CMI collaborators.

Andrew Downey
Colorado School of Mines

Aquatic Toxicity of Critical Minerals and Materials and Compounds Used in Their Recovery

As domestic production of critical minerals and materials (CMM) expands, the potential for ecological impacts may increase. CMMs, as well as chemical reagents used in CMM recovery and purification (e.g., extractants, acids, bases, buffers, solvent extraction phase modifiers, flotation agents, etc.) may enter the aquatic environment through spills or wastewater discharge. To determine possible ecological impacts, we performed toxicity tests using Daphnia magna, a freshwater invertebrate commonly used for effluent testing. We examined several CMMs (i.e. Dy, Cu, La, Ni, and Nd) and found toxicity to be highly-dependent on the CMM water solubility in the test media. Carbonate was a key component of the media that influenced toxicity by limiting CMM solubility. Laboratory measured solubility was in general agreement with predictions made by MINTEQ modeling. Two custom ligands (Acyclopa and Acyclopa-XL-OMe) currently under evaluation within CMI for selective leaching of rare earth elements were also tested. Finally, complex lixiviants containing CMMs, the ligands, and electrolytes were tested.

Rebecca Smaha presenting for Rambabu Kuchi
(Poster not judged due to presenter ineligibility)
NLR and Ames National Laboratory

Exceptional Magnetic Properties Enhancement in Scaled SmFeN Production via a Modified RD process

We demonstrated the synthesis of low-oxygen Sm2Fe17N3 powders were synthesized using both bottom-up and top-down reduction–diffusion (RD) routes. In the top-down approach, the coarse Sm2Fe17N3 powders obtained from utilizing the large Fe particle sized powders enabled effective water washing without excessive oxidation, making it suitable for scale-up. The process was expanded from ~2 g to 50 g and 100 g batches, with nitridation optimized by adjusting nitridation reaction time. Washing challenges at larger scales were mitigated by controlling Ca amounts during RD and applying hydrogenation of RD powders to promote removal of CaO byproducts. The resulting powders achieved recorded BHmax = 33.78 MGOe, Hc = 12 kOe, Mr = 144 emu/g, and Ms = 160 emu/g, is attributed to complete nitridation of Sm2Fe17 to desired single-phase Sm2Fe17N3with minimal oxygen pickup. These powders are promising feedstock for producing dense, high-energy SmFeN sintered magnets.

Nicholas Ury
Lawrence Livermore National Laboratory

Development of a Multi-component Thermodynamic Database for Molten Salt Processing of Rare Earths

Molten chloride electrochemical processing of rare earths offers an alternative to traditional extractive metallurgical routes by using less harmful chemicals, making it easier to comply with industrial regulations. It can also reduce the number of processing steps and lower the cost of extraction and separation. Electrochemical processing involves dissolving rare earth chlorides into a low melting salt mixture where species can be selectively reduced, supporting both separation and reduction. A Ca-K-Li-Na-Nd-Pr-Cl thermodynamic database was assessed to better understand the electrochemical behavior of rare earths. Multiple oxidation states of the rare earths were accounted for to model the redox shuttling behavior in electrowinning processes. Prediction of electrochemical reduction potentials and phase equilibria during electrochemical processing will also be performed.

Justin Wilbanks
Northern Arizona University

Uranium and Critical Material Analysis of Water and Algae from Western Navajo Nation

The purpose of this research is to quantify the concentrations of uranium, arsenic, and rare earth elements in water and algae from the western Navajo Nation. These elements are of interest for the role they play in human health and their environmental impact through bioaccumulation.
Through the mid-1900s, the Navajo Nation was the top supplier of domestic uranium for the United States. Today, hundreds of mine sites remain abandoned, leading to health and environmental concerns among the Navajo people.

Water samples were collected from 50 sites in the Western Navajo Agency with the help of community members. Sample concentrations were analyzed by inductively coupled plasma mass spectrometry using an Agilent 8900 Triple Quadrupole ICP-MS.
Results show a majority of wells below the EPA maximum contamination limits for uranium and arsenic in water. Wells exceeding MCL are in close proximity to mine features. Algae collected at 8 sites shows concentrations several times greater than the surrounding water. Algae are known to accumulate uranium and other metals and may impact the concentration of water, especially in wells accessed by livestock which are open to the environment.

Sylvia Hasley-Velez
Pacific Northwest National Laboratory

REE Extraction from Phosphoric Acid Production Byproducts

Increasing demand for critical materials including rare earth elements (REE) and the U.S. reliance on imports have driven efforts to explore REE production from industrial processes phosphate mining. About 25 million tons of the phosphate rock, containing up to 0.1wt% REEs, is mined annually within the U.S., with phosphogypsum (PG) and evaporation sludge (ES) as byproducts from the phosphoric acid production. These byproducts accounting for approximately 35-70% and 15–30% of the REEs from phosphate ore, respectively. The distinct chemical matrices (CaSO4 for PG and P2O5 for ES) pose challenges in REE recovery. Once successful REE leaching is established, feeds from both materials can undergo similar solvent extraction process using the same organic solvent which can help reduce waste and environmental impacts. This overview highlights advancements in REE recovery from PG and ES, including batch solvent extraction testing, the application of AMUSE modeling to dynamic flow processes, and the use of centrifugal contactors. Furthermore, these methods developed for PG can potentially be adapted for the recovery of critical materials from other industrial byproducts.

Trevor Lewis
Colorado School of Mines

Financial Impact of Critical Mineral Designation

The goal of this presentation is to reveal how critical mineral designations impact mining firms. This is undertaken using a financial event study methodology, where the stock price of a firm is compared to a basket of related stocks’ prices before and after new information, in this case, a critical mineral designation, hits the market. Cumulative abnormal returns, price increases for the mining firm’s stock above those predicted, are calculated to determine how the market values the ability to produce minerals designated as critical.

Victor Oghenekohwo
Oak Ridge National Laboratory

Automated Screening of Extractant Physical Properties Relevant to the Recovery of Critical Metals

To mitigate supply risks associated with the production of critical metals, it is necessary to develop rapid and efficient methods for their separation and recovery. In this study, we demonstrate the automation of biphasic potentiometric titration experiments to directly measure the pKa of extractants in the organic phase. Specifically, we consider organophosphorus acidic extractants and hydrophobic organic solvents to reflect real-world separation and extraction systems. Herein, we emphasize the role of automation in enhancing the precision and throughput of the experiments. Our approach leverages a combination of laboratory hardware (Syringe pumps, pH electrodes) and open-source software (LabVIEW, Python, and Rxn Rover®) to create a new modular system that can automatically perform titrations and analyze the data, hence, closing the experiment loop. The data analysis is performed using pKaScope, a Python package which was developed in-house as a modification of the Stable Numerical Solution to the Adsorption Integral Equation using B-Splines (SAIEUS) algorithm to comprehensively account for key titration parameters, including aqueous phase ionic strength.

Weston Hartzell
Missouri S&T

Gallium Recovery from Acidic Solutions: Overcoming Iron Interference

Gallium (Ga) has been listed as a Department of Energy Critical Material due to its importance to energy and supply risk in both the near- and medium-term time frames. Due to the primary source of Ga being associated with non-allied entities, a sustainable domestic supply is needed. In this work, we investigate an industrially relevant pathway for Ga recovery from acidic industrial sulfate solution, which contain low-concentration Ga alongside high levels of iron (Fe) originating from zinc (Zn) production processes. Solvent extraction (SX) to recover Ga from acidic solutions has been demonstrated but suffers due to overlapping affinities of Ga(III) and Fe(III). To overcome this limitation, a reductive pre-treatment process utilizing Zn powder to reduce Fe(III) to Fe(II) has been studied in conjunction with a range of commercially available extractants to suppress iron co-extraction and enhance Ga selectivity.

Yaroslav Mudryk
Ames National Laboratory

Controlled Oxygen Content in Ca-RD–Prepared NdFeB Powders for High-Performance Magnet Fabrication

A calciothermic reduction–diffusion (Ca-RD) route using Nd2O3, Ca, Fe, FeB, and a Ca-based dispersant produces high-quality, phase-pure NdFeB powders. The materials achieved >96% phase purity, 155–165 emu/g saturation magnetization, and <1.0% oxygen content. Effective removal of reaction byproducts through optimized washing protocols yields powders with high magnetization suitable for industrial use. Controlling the oxygen content in NdFeB powders synthesized via the Ca-RD process is feasible by incorporating larger Fe particles and optimizing the washing procedure. The resulting magnet exhibited an energy product of 16.35 MGOe and a remanence of 12.16 kG though coercivity remained low. These encouraging outcomes suggest that additional gains in performance are achievable through grain-boundary engineering and particle refinement. Any meaningful improvement in coercivity by particle engineering will immediately bring this product closer to commercialization.

Sameer Kulkarni
Idaho National Laboratory

Leveraging Domain-Specific AI for Supply Chain Analysis

Global supply chains face mounting vulnerabilities, as demonstrated by the COVID-19 pandemic, trade route disruptions, and geopolitical conflicts. These challenges are particularly acute for critical materials essential to energy technologies. Traditional analytics struggle with fragmented information and the interdisciplinary complexity spanning geopolitics, markets, and engineering.