The mineral deposits at Bear Lodge contain both the magnet rare earth materials neodymium, praseodymium, samarium and terbium as well as cerium (Ce), lanthanum, yttrium, gadolinium, europium and dysprosium. All these elements are on the U.S. Geological Survey`s list of 60 critical minerals. The minerals on the list have been identified as critical due to their role in national security or economic development and by their risk of supply chain disruption.

The project details

The vertically integrated Bear Lodge Rare Earth Project encompasses mining of rare earth element (REE) ore which will become feed material for a state-of-the-art commercial processing facility. The facility will produce high-purity separated neodymium-praseodymium (NdPr) oxide using the company`s patented, environmentally friendly technology. It will be designed as a zero discharge facility and will located approximately 40 miles from the mining area.

The full scale commercial processing facility will be built based on the operational, economic, and engineering data derived from the demonstration plant. This US Nuclear Regulatory Commission certified plant is located at Upton, Wyoming.

Ken Mushinski, President and CEO of RER said “The primary objective of a Demonstration Plant is to systematically uncover and resolve mechanical and operational challenges before scaling to a commercial facility”.

He further said “By fine-tuning our primary processing circuit and resolving these filtration inefficiencies now, we are effectively de-risking our commercial trajectory. Once this front-end optimization is complete, the primary circuit will continuously feed our completed separation circuits to yield high-purity NdPr.

The separation process

According to the company the proprietary separation process involves four steps. It commences by crushing and screening of the feed sample to 1mm size followed by counter-current leaching and selective precipitation, to chemical digestion and solvent extraction, and finally to REE separation and refining.

The final REE separation and refining process involves multiple steps, these remove the Nd/Pr (at greater than 99.5 percent purity) as well as samarium, europium, gadolinium, lanthanum and heavy rare earth concentrates.

The company states that it has done extensive laboratory bench-scale and pilot plant testing on metallurgical processes to recover saleable rare earth products and has been granted two patents on its metallurgical processing. These involve removal of thorium from REE containing acidic solution, as well as the selective extraction of REEs using oxalic acid. These patented processes have been further advanced in collaboration with General Atomics, the company’s majority shareholder.

Supply chain context

The United States currently has limited domestic capacity for separating and processing rare earth elements into refined oxides or metals. Mountain Pass in California remains the only operating rare earth mine in the country, though its concentrate is largely shipped to China for separation (which accounts for 91 percent of the global refined output). Projects like Bear Lodge are positioned as potential contributors to a more complete domestic supply chain, from ore to separated material.

Although permitting timelines, metallurgical recovery rates, and sustained financing are the primary variables that determine whether a deposit moves from resource estimate to operating mine.

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