Vertical integration
In addition to advancing two ionic clay rare earth projects in South America, Aclara is building out the entire value chain—from mine to magnet:
Aclara is advancing the development of a rare earths separation facility in the United States through its wholly owned subsidiary, Aclara Technologies Inc. This plant will process mixed rare earth carbonates produced from Aclara’s mineral resources, separating them into high-purity individual rare earth oxides. Aclara’s solvent extraction-based separation flowsheet was designed in collaboration with the Saskatchewan Research Council. This innovative process formed the basis for Hatch to complete a Class 5 AACE capital and operating cost estimate, incorporating key environmental safeguards such as significant waste reduction and a zero-liquid-discharge system. These early results are highly promising and position Aclara to become the first vertically integrated producer of heavy rare earths outside of Asia.
Technical study highlights
• Separation of key Rare Earth Elements (REEs): The study evaluates the separation of mixed rare earth carbonates (MREC) from Aclara’s Carina Project and Penco Module into high-purity individual oxides of neodymium-praseodymium (NdPr), dysprosium (Dy), and terbium (Tb).
• Proven technology: Utilizes a solvent extraction process based on hydrochloric acid chemistry, a well-established and effective method for rare earth separation.
• High purity: The process achieves over 99.5% purity across all separated rare earth oxides.
• Strong metallurgical recoveries: Expected recoveries are 94% for NdPr, 92% for Dy, and 91% for Tb.
• Environmental sustainability: Designed for full water recirculation, resulting in zero liquid discharge and minimizing environmental impact.
• Preliminary CAPEX and OPEX estimates:
- Total estimated CAPEX: US$ 354 million includes US$ 244 million for the solvent extraction plant and US$ 110 million allocated to waste reduction and achieving zero liquid discharge
- Estimated OPEX: US$ 12 per kilogram of rare earth oxides (REO)
• Integration with Circular Mineral Harvesting: The project benefits from strong synergies with Aclara’s proprietary Circular Mineral Harvesting process, enabling:
- Lower CAPEX and OPEX across both mining and separation stages
- Reduced waste management costs
- Improved MREC quality from both the Carina Project and Penco Module
Next steps
• Trade-off chemistry study: Evaluating hydrochloric acid versus nitrate-based chemistries to determine the optimal flowsheet configuration.
• Location study: Working with the U.S. Department of Commerce’s International Trade Administration to identify the most strategic site for the facility, focusing on cost, logistics, and permitting timelines.
• Metallurgical testing & optimization: Conducting bench-scale and mini-pilot tests to optimize flowsheet performance and refine CAPEX and OPEX estimates, leading to a potential integrated piloting campaign and Class 3 AACE engineering study.
In today’s geopolitical environment, rare earth separation capabilities—particularly with a balanced heavy and light feed—are considered a strategic asset. As a result, Aclara is actively engaging with multiple governments interested in supporting the development of this project.
Target milestones for 2025:• Completion of the U.S. plant location study
• Laboratory test work (Q2 2025)
• Integrated pilot scale testing (Q3–Q4 2025)
Aclara is expanding its rare earths value chain through Aclara Metals, a joint venture with CAP S.A., its strategic partner in Chile. The objective is to produce rare earth metals and alloys that meet the specifications required by permanent magnet manufacturers—particularly in the electric vehicle (EV) sector.
The facility will utilize rare earth oxides from Aclara’s mining and separation processes to manufacture high-purity alloys tailored to magnet production. Developed in close collaboration with the Engineering Department at Huachipato (CAP S.A.’s steelmaking subsidiary), the program integrates Huachipato’s metallurgical expertise with international site visits and pilot-scale production campaigns.
Notably, the team has already achieved low-volume production of metallic dysprosium and developed a conceptual flowsheet for full-scale metals and alloys production. The industrial facility will adapt proven metallurgical technologies while meeting stringent emissions and environmental standards.
Key processes under evaluation
•Electrolytic reduction: Production of NdPr alloy with 99.5% purity and ferro-dysprosium.
•Vacuum induction melting: Production of metallic terbium with 99.4% purity.
•Strip casting furnace: Alloy production incorporating NdPr, Dy, and Tb.
Next Steps
• Pilot plant design (Q2 2025): Design finalized to evaluate key process parameters, reduce technological risk, and validate product quality.
• Location analysis (Q3 2025): Assess site-specific factors including emissions, regulatory requirements, and material handling considerations.
• Conceptual engineering (Q3 2025): Completion of engineering work based on pilot testing, in collaboration with Huachipato and external technical advisors.
• Pre-Feasibility Study (Q4 2025): A comprehensive technical and economic assessment to validate project viability and inform a potential full feasibility study.
Aclara's vision is to become the foudation of a sustainable value chain fot technologies that are integral to the world's green energy transition
