Rare earth elements (REEs) are crucial to the production of green energy motors in wind turbines, hybrid cars, electric vehicles, and electronic device. REEs are also 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 this DOE SBIR Phase 1 project, we will produce REMs from REOs by recycling of rare earth materials from post-consumer products. Of the five critical REEs, [dysprosium (Dy,66), neodymium (Nd,60), terbium (Tb,65), europium (Eu,63), and yttrium (Y,39)] [2], we will target on Nd, Y, and Dy, and also Sm, Ce, two other popularly used REMs. A novel very efficient and low energy consumption technology will be developed for five most valuable REMs (Nd, Y, Dy, Sm, Ce) production from their corresponding oxides by aluminum powder reduction (direct production of Ce, and removal of other non REMs contamination) and catalytic reduction with hydrogen and enhanced by non-thermal plasma. This is the first time that thermite reaction is introduced into the REMs industry for non-REE metals (impurities) removal. The PI has extensive experience on thermite reactions; he led an industrial project on thermite application in 2015 and demonstrated thermite reaction for science fair. The experimental data in this project will provide the basis for future process scale up and modular plant design to produce commercial quantities of REMs. A preliminary techno-economic assessment (TEA) will be performed to provide a process flow sheet and conceptual costs for REMs production.
