Rare earth metal production scaling using REMAFS

CMI researchers from Ames National Laboratory and Terves conducted the activity for this highlight

Innovation 
Large-scale production of neodymium metal (>0.5 kg) and didymium metal (≥ 1.0 kg) was achieved via metallothermic reduction of sodium rare earth fluoride, NaNdF4 or Na(NdPr)F4, as the feedstock.

Achievement

  • The REMAFS method enables scalable rare earth metal production by eliminating hydrogen fluoride in salt synthesis and reduction.
  • By completely avoiding hydrofluoric acid (HF), REMAFS provides a safer, more environmentally sustainable alternative for rare earth metallothermic reduction processes.

Significance and Impact

  • Demonstrated kilogram-scale production of rare earth metal (Nd and NdPr) from feedstock without using or generating hazardous chemicals.
  • Supports domestic Nd metal and Nd-Fe-B magnet production.

Hub Target Addressed  
Energy-efficient rare earth metals production.

image of metal ingot, jar of powder and a ruler
Sodium neodymium fluoride salt (right), used in the REMAFS (Rare Earth Metals from Alternative Fluoride Salt) process, with >0.5 kg of neodymium metal produced (left).