Brazilian Rare Earths has confirmed a breakthrough low-temperature acid-cure process achieving up to 97% rare earth extraction at just 150°C, promising lower costs and enhanced scalability for its Brazilian operations.
- 97% extraction rate for total rare earth oxides and uranium at 150°C
- Low-temperature acid-cure process replaces energy-intensive high-temp kilns
- Integrated system yields ~91% total rare earth oxide recovery from mineral to product
- Process scalability validated with 15 kg composite test replicating lab results
- Ongoing optimisation and pilot plant upgrades underway to support commercial scale-up
A Breakthrough in Rare Earth Processing
Brazilian Rare Earths Limited (ASX – BRE) has announced a significant metallurgical advancement that could reshape the economics of rare earth extraction in Brazil. The company’s latest metallurgical optimisation program, conducted at Brazil’s CDTN research institute, validated a low-temperature acid-cure process operating at just 150°C. This process achieved exceptional extraction rates of up to 97% for total rare earth oxides (TREO) and uranium, rivaling or exceeding conventional high-temperature methods.
Unlike traditional hard-rock rare earth processing that relies on rotary kilns operating above 250°C, Brazilian Rare Earths’ approach uses a simplified, low-energy flowsheet. This innovation promises to reduce both capital expenditure and operating costs by eliminating the need for energy-intensive thermal cracking and complex off-gas treatment systems.
Integrated Mine-to-Product Efficiency
The acid-cure process is a key component of an integrated value chain that begins with high-yield ore sorting at the Monte Alto deposit, followed by hydrometallurgical processing at the company’s centralised Camaçari refinery hub. When combined with ore sorting recoveries exceeding 95%, the total system yields approach 91% for rare earth oxides and 89% for uranium, underscoring the efficiency of the end-to-end process.
Managing Director and CEO Bernardo da Veiga highlighted the importance of these results, stating that the process “supports the engineering simplicity required for scalable deployment” and unlocks value from the high-grade mineralisation across the Rocha da Rocha province. The company is now focused on applying this flowsheet to a broader resource base, aiming to integrate multiple high-grade feedstocks into a flexible 'hub-and-spoke' production platform.
Validation and Scalability Confidence
The metallurgical program included a 15 kg blended composite test that replicated laboratory-scale extraction rates, providing strong confidence in the process’s scalability. The testing confirmed that increasing the curing temperature beyond 150°C to 200–250°C offered no additional recovery benefits, reinforcing the efficiency of the low-temperature approach.
Further optimisation opportunities remain, including shortening wash durations and refining acid usage, which could enhance performance while maintaining high extraction rates. Brazilian Rare Earths is also collaborating with partners such as ANSTO and Carester to benchmark alternative process pathways and upgrade the SENAI CIMATEC pilot plant, positioning Brazil as a future rare earth processing hub.
Implications for the Rare Earth Sector
This development is particularly timely given the global strategic importance of rare earth elements, critical for technologies ranging from electric vehicles to renewable energy systems. Brazilian Rare Earths’ low-temperature process could set a new standard for cost-effective, scalable rare earth production, reducing environmental and energy footprints compared to conventional methods.
While the results are promising, the company acknowledges that further scale-up testing and feedstock flexibility validation are underway. The next phases will be crucial in confirming commercial viability and securing the pathway to production.
Bottom Line?
Brazilian Rare Earths’ low-temperature breakthrough could redefine rare earth processing economics, but the next scale-up steps will be pivotal.
Questions in the middle?
- How will the low-temperature process perform across different feedstock types beyond Monte Alto?
- What are the timelines and capital requirements for commercial-scale plant deployment?
- How might this process impact Brazil’s position in the global rare earth supply chain?