Flash Joule Heating Cuts Rare Earth Recycling Costs by Over 50%, Boosts Purity

A Breakthrough in Rare Earth Recycling

Metallium Limited has announced a significant advancement in the recovery of rare earth elements (REEs) from end-of-life magnets, leveraging a novel method developed by Rice University researchers. This technique, known as Flash Joule Heating combined with chlorination (FJH-Cl₂), promises to revolutionize the recycling of critical metals by delivering high purity and yield in mere seconds; dramatically faster than traditional methods.

Unlike conventional hydrometallurgical processes that rely on prolonged acid leaching and solvent extraction, Metallium’s approach eliminates the need for acids and water, cutting energy consumption by 87% and greenhouse gas emissions by 84%. The process also reduces operating costs by 54%, making it both environmentally and economically compelling.

From Lab to Pilot Plant

Metallium holds exclusive rights to commercialize this technology and is preparing to trial it in its Texas pilot prototype system. This step is critical in transitioning the breakthrough from peer-reviewed laboratory success to scalable industrial application. The pilot plant, located at the Texas Technology Campus, will serve as a hub for ongoing research and development, with the goal of establishing a national network of clean-tech metal recovery facilities anchored in the United States.

The process works by rapidly heating demagnetized magnet powders on a conductive carbon substrate in the presence of chlorine gas. This causes transition metals like iron and cobalt to form volatile chlorides that are removed, while rare earth oxides convert to stable oxychlorides, concentrating the valuable elements in a single, swift step.

Strategic Implications for Supply Chain Independence

Permanent magnets made from neodymium-iron-boron (NdFeB) and samarium-cobalt (SmCo) are essential in electric vehicles, wind turbines, and defense systems. However, nearly all refining and recycling capacity currently resides in China, which has recently tightened export restrictions on rare earth materials and related technologies. Metallium’s innovation, combined with its partnership with Ucore Rare Metals, offers a pathway to a fully U.S.-based rare earth refining capability, reducing reliance on Chinese supply chains.

This modular and flexible refining system can process a variety of feedstocks, including mine concentrates and magnet scrap, positioning Metallium at the forefront of efforts to secure critical mineral supply chains for Western industries.

Environmental and Economic Benefits

The environmental advantages of the FJH-Cl₂ process are striking. By eliminating acid and water use, the method avoids the large wastewater streams typical of hydrometallurgical recycling. The rapid processing time also means lower energy consumption and fewer emissions, aligning with global goals for sustainable resource management.

Moreover, the process generates commercially valuable by-products such as cobalt chloride and ferric chloride, adding potential revenue streams and enhancing overall economic viability.

Looking Ahead

Metallium’s next phase will focus on scaling the technology through its Texas pilot plant, aiming to demonstrate commercial viability and attract further investment. Success here could mark a turning point in the rare earth recycling industry, offering a cleaner, faster, and more cost-effective alternative to existing methods and strengthening the resilience of critical metal supply chains outside of China’s influence.