Project Summary
A South American-Canadian resource development company engaged our consulting engineering firm to support its efforts in extracting rare earth elements (REEs) from ionic clay deposits in South America. The objective was to develop a technically viable and environmentally responsible process for REE recovery from these clay-hosted ores. Our involvement encompassed process development, advisory services, and reporting support in alignment with regulatory and industry standards.
Challenge
Ionic clay deposits present a unique opportunity for REE extraction due to the loosely bound nature of rare earth ions, but they also pose distinct challenges. These include achieving high extraction efficiency, controlling impurity levels, managing reagent consumption, and ensuring sustainability through water reuse. The client required a tailored solution that would enable consistent recovery of REEs while supporting both economic and environmental goals.
Solution
Our team delivered a comprehensive process solution comprising the following key elements:
Leaching Process Development
Designed and optimized the use of reagents for efficient extraction of Rare Earths from ionic clays.
Impurity Removal
Engineered a purification stage to remove impurity elements prior to REE recovery.
REE Precipitation:
Developed a controlled precipitation process to recover REEs as carbonates, optimizing for purity and yield.
Water Recycling System:
Implemented a closed-loop water system to minimize environmental impact and reduce operational costs.
Engineering Support:
Contributed to the pre-feasibility study and the preparation of a compliant NI 43-101 technical report.
Flowsheet Development:
Created a detailed process flowsheet incorporating all major unit operations and water management strategies.
Key Results
Process Efficiency
Demonstrated high REE recovery rates under optimized leaching conditions.
Technical Reporting:
Delivered NI 43-101 compliant documentation in support of the client’s project advancement and stakeholder and investor communications.
Scalability:
Designed the process to be adaptable for future pilot-scale and commercial operations in multiple geographies.
Business Impact
Our work enabled the client to:
- Advance its rare earth development strategy in Americas with confidence in process viability.
- Reduce technical uncertainty and streamline regulatory compliance through robust documentation.
- Position itself as a leader in sustainable Rare Earth extraction from ionic clays, with a focus on low-impact, high-efficiency operations.
This project represents a key step toward establishing a sustainable and responsible rare earth supply chain outside traditional production regions.
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