The US Effort to Break China's Rare-Earth Monopoly

The New York Times checks in on U.S. university researchers and start-ups trying to create domestic rare-earth processing facility:

There is too little money to be made in rare earths for the elements to be of much interest to mining giants, so the challenge of reestablishing a domestic industry has fallen to small companies like Phoenix Tailings, a Boston-area startup that runs the metal-making plant in Exeter, New Hampshire. A handful of other companies in the United States are processing rare earths in small quantities, including MP Materials, which owns a mine in Mountain Pass, California, and recently began producing rare-earth metal in Fort Worth, Texas. Similar efforts are underway in Europe and Asia. 'It's small volumes of low-value materials that are very expensive to process,' said Elsa Olivetti, a materials science and engineering professor at the Massachusetts Institute of Technology. 'Meaning it's hard to make money.'

Phoenix Tailings' New Hampshire operation is about 2 months old, housed in a converted medical device plant. The company buys metric-ton bags of powder — a mixture of neodymium and praseodymium bound with oxygen — from mining and refining companies in the United States, South America and Australia. It funnels that flour-like material into a drying oven and eventually into furnaces that heat it to the temperature of volcanic lava. This circuit takes up less than 15,000 square feet and is designed to generate no emissions other than those associated with the electricity Phoenix Tailings uses. The closed-loop design distinguishes this process from the more energy-intensive techniques used in China, where workers scoop up molten metal with ladles. That approach releases perfluorocarbons, potent greenhouse gases that do not break down easily.


In late 2024 the company was three weeks from bankruptcy — but it's recently been valued at $189 million.

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