The Dawn of a New Era in Rare Earth Extraction

South Africa's Phalaborwa Rare Earths Project marks a pivotal moment in the global quest for sustainable critical minerals supply. Located in Limpopo Province, this innovative facility transforms decades-old industrial waste into valuable rare earth elements, essential for electric vehicles, wind turbines, and defense technologies. By reclaiming phosphogypsum stacks from a former phosphate mine, the project exemplifies circular economy principles, turning environmental liabilities into economic assets.

Rainbow Rare Earths, the driving force behind the initiative, leverages a hydrometallurgical process that involves acid leaching, impurity removal, and solvent extraction to produce separated oxides like neodymium-praseodymium (NdPr) and heavy rare earth carbonates. With a resource base of 35 million tonnes grading 0.44% total rare earth oxides (TREO), the site promises up to 1,850 tonnes per annum of NdPr oxide upon full ramp-up.

South Africa's Untapped Rare Earth Potential

The country boasts significant rare earth deposits, including monazite-rich tailings and coal byproducts, positioning it as a key player outside China's dominant 80-90% market share. Phalaborwa stands out due to its low-cost model—estimated operating expenses under $30 per kg NdPr equivalent—made possible by pre-existing waste processing.

Phosphogypsum, a byproduct of phosphate fertilizer production, contains REEs concentrated through geological processes in the unique Phalaborwa Igneous Complex. Traditional mining is energy-intensive, but this secondary source recovery minimizes new excavation, reducing carbon footprints by up to 90% compared to primary deposits.

Groundbreaking Extraction Technology at the Core

The technique employs sulfuric acid leaching at mild conditions (30-40°C, 110 g/L acid, 8-hour residence), followed by cation ion exchange (CIX) for fluoride removal and solvent extraction for separation. Proven by pilot-scale testwork, it achieves 65% overall recovery, yielding high-purity products suitable for magnet manufacturing.

This approach addresses key challenges like low REE concentrations (0.36% in phosphogypsum) and impurities, making viable what was once uneconomic. For more on the process flowsheet, visit the Rainbow Rare Earths Phalaborwa page.

University Research Fueling Innovation

South African higher education institutions have been instrumental. At the University of Pretoria, researchers R.A. Wildenboer and R.F. Sandenbergh demonstrated effective REE leaching from Phalaborwa phosphogypsum under ambient conditions, validating the core hydrometallurgical steps. Their 2024 study highlights solid-solution REEs in gypsum, leachable without extreme measures.

The University of the Witwatersrand (Wits) explores REE recovery from acid mine drainage (AMD), a parallel waste stream rich in critical minerals. Using ion exchange resins, Wits teams tackle iron interference, informing scalable purification tech transferable to phosphogypsum processing. Explore their work here.

• Low-concentration REE extraction challenges addressed via selective resins.
• Phytoremediation potential for soil-bound CRMs.
• Collaborative pilots with industry partners like Cwenga.

Mintek, South Africa's mineral research hub, conducted pivotal SX modeling and leach optimization for Phalaborwa, bridging academia and industry. Partnerships with the National Research Foundation (NRF) amplify university-led R&D in critical minerals.

Collaborations Between Academia and Industry

Rainbow Rare Earths partners with Mintek and the Australian Nuclear Science and Technology Organisation (ANSTO) for validation, but university theses and labs provide foundational data. The University of Johannesburg (UJ) analyzes REE modes in coals, while UCT's Minerals to Metals Initiative trains postgrads in extractive metallurgy via MPhil programs.

These ties foster knowledge transfer: student projects on coal fly ash REEs inform national strategies, as Mintek pioneers recovery from such wastes. Details on Mintek's efforts here.

Economic Impacts and Job Opportunities

With US DFC's $50 million via TechMet and potential $266 million loan guarantees, the project spurs 500+ direct jobs in processing and engineering. Universities like Wits and UP supply skilled graduates in chemical engineering and geosciences, with demand surging for minerals processing experts.

South Africa's critical minerals strategy eyes REEs for GDP growth, creating research positions and spin-offs. Phalaborwa's 16-year mine life ensures sustained academic-industry pipelines.

Training the Next Generation of Experts

SA universities ramp up programs: Wits' Minerals Engineering, UP's Metallurgical Engineering, and UCT's MPhil equip students with hydrometallurgy, SX, and sustainability skills. Internships at Mintek and Rainbow bridge theory to practice, addressing skills gaps in REE value chains.

• Hands-on labs simulating acid leach and SX circuits.
• Collaborative theses on waste valorization.
• NRF bursaries targeting critical minerals PhDs.

This facility opening accelerates curriculum updates, integrating REE case studies.

Environmental and Sustainability Benefits

Remediating 35 million tonnes of radioactive phosphogypsum reduces legacy hazards, with benign gypsum byproduct repurposed for construction. Low-energy process (90% renewables targeted) aligns with net-zero goals, showcasing uni research on green extraction.

Global Geopolitics and Supply Chain Security

As China controls 90% of REE refining, Phalaborwa diversifies Western supply, prioritizing US defense needs per CEO George Bennett. AP coverage details US backing amid diplomatic tensions.

Challenges Ahead

Financing hurdles, thorium management, and market volatility persist. Universities advocate policy support for R&D funding to scale tech.

Future Outlook for SA Higher Education

Phalaborwa heralds a boom in minerals research hubs, with unis positioning SA as REE leader. Expect more PhDs, spin-outs, and global partnerships, driving innovation in green tech.

Photo by Simone Busatto on Unsplash