Department of Energy Innovation Hub Selects Seven Critical Materials Projects
The U.S. Department of Energy’s Critical Materials Innovation Hub (CMI) has selected seven new projects through a competitive open call. These projects will accelerate transformational advances in the science and engineering necessary to reduce material criticality for energy innovation, with specific emphasis on industrial relevance, participation and adoption.
“The addition of these projects will strengthen and expand our R&D portfolio by developing capabilities and expertise across supply chain stages of materials,” says CMI Director Tom Lograsso. “These projects expand the number of CMI Team members, welcoming new industry and university partners in addition to proposals led by current university and national laboratory partners.”
The projects selected for award negotiations address scientific gaps and technical barriers to the establishment of domestic supply chains in these areas: environmentally benign rare earth metal and alloy production; efficient gallium byproduct recovery, separation and concentration; and improved copper sulfide leaching to unlock copper resources in historic heaps. The lead organizations and project titles are:
- University of Arizona: A synergistic approach using nanobubbles, surfactants, and reactive oxygen species to enhance copper sulfide leaching
A synergistic approach using nanobubbles, surfactants, and reactive oxygen species to enhance copper sulfide leaching: University of Arizona with Penn State
This project will improve copper recovery by combining three technologies: nanobubbles to increase dissolved oxygen, surfactants to improve solution flow through ore, and UV-generated reactive compounds that accelerate copper release. Researchers will conduct laboratory testing and modeling to optimize the process and better understand copper dissolution. The goal is to create a practical, scalable extraction method that boosts copper recovery by at least 30% while improving the efficiency and sustainability of copper production.
- Colorado School of Mines: Improving copper extraction from primary copper sulfides using hydro and bio-hydro metallurgical processes
Improving copper extraction from primary copper sulfides using hydro and bio-hydro metallurgical processes: Colorado School of Mines with Michigan Technical University, 1849 Bio, Newmont
This project seeks to improve copper recovery from chalcopyrite, the most abundant copper-bearing mineral. Researchers will evaluate activated carbon, alternative leaching solutions, and additives to enhance copper extraction under conditions used in large-scale mining. The team will study naturally occurring and engineered microorganisms that help break down minerals and release copper more efficiently. Supported by industry partners Newmont and 1849 Bio, the project aims to develop a scalable process that increases recovery from lower-grade resources and strengthens domestic copper production.
- Case Western Reserve University: Process intensification enabled by chloride-based molten salt electrolysis for highly efficient heavy rare earth metal production
Process intensification enabled by chloride-based molten salt electrolysis for highly efficient heavy rare earth metal production: Case Western Reserve University with Lawrence Livermore National Laboratory (LLNL), Ames National Laboratory (Ames), Energy Fuels, MP Materials, Galvanix, University of Arizona, Current Chemicals, AML
This project will develop a more efficient and environmentally friendly method for producing dysprosium (Dy) and terbium (Tb) metals. Using domestically sourced rare earth materials and a patented low-temperature molten salt electrolysis process, the team will directly convert rare earth compounds into high-purity metal. The approach could reduce energy use, eliminate multiple processing steps, and avoid toxic chemicals.
- Fast Metals: Creating new domestic sources of critical minerals: Gallium and rare earth mixed oxides from industrial byproduct residue streams
Creating new domestic sources of critical minerals: Gallium and rare earth mixed oxides from industrial byproduct residue streams: Fast Metals with Element USA, Worcester Polytechnic Institute (WPI), National Laboratory of the Rockies (NLR)
FAST Metals is developing technology to recover gallium and rare earth elements from bauxite residue, or “red mud,” an industrial byproduct of aluminum production. Building on an existing process that recovers iron, alumina, and titanium, the company plans to expand recovery to additional critical minerals and potentially other waste streams. With access to more than 30 million metric tons of stored residue in Louisiana, the project could create new domestic sources of critical materials while reducing waste, costs, and environmental impacts.
- Indium Corporation: Improved ion-exchange resin for gallium extraction from bauxite-alumina processing
Improved ion-exchange resin for gallium extraction from bauxite-alumina processing: Indium Corporation and Ames National Laboratory
This project aims to strengthen the domestic gallium supply chain by improving recovery from Bayer liquor, a byproduct of aluminum production. Indium Corporation and Ames National Laboratory will develop advanced ion-exchange resins that selectively capture gallium more efficiently and cost effectively than current methods. Using artificial intelligence, automation, and high-throughput testing, researchers will rapidly design and evaluate promising materials. The best candidates will be tested with industrial samples and assessed for long-term durability under real-world operating conditions.
- Oak Ridge National Laboratory: Transforming selective separation and recovery of gallium from zinc refinery residues using solid-phase extraction
Transforming selective separation and recovery of gallium from zinc refinery residues using solid-phase extraction: Oak Ridge National Laboratory with University of Tennessee-Knoxville (UTK) and Nyrstar
This project seeks to improve domestic gallium supply by developing advanced resin-based materials that selectively recover gallium from industrial processing streams and zinc refinery residues. Researchers will combine computer modeling, machine learning, and laboratory testing to identify and optimize materials that perform efficiently in harsh chemical environments. The team will evaluate recovery rates, processing speed, and durability through repeated cycles and will demonstrate the technology using real refinery residues to assess its commercial deployment potential.
- University of Illinois – Urbana Champaign: Development of redox-adsorbents for the selective electrochemical recovery of gallium from mining byproducts and end-of-life waste
Development of redox-adsorbents for the selective electrochemical recovery of gallium from mining byproducts and end-of-life waste: University of Illinois – Urbana Champaign with Valor Metal Inc., Glencore, Elemental Holdings SA
This project will develop advanced electrochemical materials to recover gallium from aluminum and zinc production byproducts and waste streams. The materials are designed to selectively capture and release gallium in challenging industrial conditions, improving recovery while reducing waste. Researchers will test the technology in bench-scale systems and evaluate its economic potential for large-scale deployment. Working with industry partners, the team aims to achieve more than 90% gallium recovery while producing high-purity material at lower operating costs.