Scalable synthesis of K-RE-F salts for rare earth metal production

CMI researchers at Ames National Laboratory conducted the activity for this highlight

Innovation 
Scalable, environmentally friendly, cost-effective method of generating feedstock potassium-rare earth fluorides without using or generating HF.

Achievement

  • Scalable production of over 500g of water-free K-Nd-F salt
  • Synthesis of more than 100 g of water-free KREF4 analogs (RE = Pr, Tb, Dy)
  • Threefold reduction in wastewater generation relative to Na-RE-F processing

Significance and Impact

  • Domestic production of rare earth element feedstocks for secure and resilient processing
  • Supports U.S.-based production of NdFeB permanent magnets

Hub Target Addressed 
Advancing efficient and cost-effective REE production.

Figure: XRD pattern of KREF4 series where RE: Pr, Nd, Tb, Dy, demonstrating formation of desired feedstock phase (Phase assignments: C = cubic; H = hexagonal).
Figure: XRD pattern of KREF4 series where RE: Pr, Nd, Tb, Dy, demonstrating formation of desired feedstock phase (Phase assignments: C = cubic; H = hexagonal).