Understanding Rare Earth Minerals and Their Significance

In February, former US President Donald Trump expressed interest in Ukraine providing rare earth materials to the U.S. as part of financial assistance for Kyiv’s military efforts against Russia.

This statement aligns with a component of a military strategy known as the “victory plan,” introduced by President Volodymyr Zelensky to Ukraine’s allies, including Donald Trump, last year.

The strategy aims to forge partnerships with foreign allies to facilitate joint access to Ukraine’s strategically important resources.

It remains unclear whether Trump was referencing a broad array of critical minerals or focusing specifically on rare earth elements. He indicated that the U.S. is pursuing a deal with Ukraine for “their rare earths and other materials.”

Rare earths are a collection of 17 metals essential for creating magnets that convert power to movement in electric vehicles, smartphones, military systems, and various other electronic devices. No alternatives exist for these materials.

China dominates the global production of rare earths and many other essential minerals.

Trump has also shown interest in incorporating Greenland, an autonomous region of Denmark with sizable rare earth deposits, into the United States since his re-election bid.

The U.S. Geological Survey lists 50 minerals as critical, which includes various rare earth types, nickel, and lithium.

According to data from the Ukrainian economy ministry, Ukraine possesses deposits of 22 out of the 34 minerals classified as critical by the European Union. These deposits include industrial and construction materials, ferroalloys, precious and non-ferrous metals, and select rare earth elements. While Ukraine also has substantial coal reserves, many are currently under Russian control in occupied regions.

Why Are Rare Earths Significant?

The 17 rare earth minerals, which are a light silvery-white color, are not particularly scarce in the Earth’s crust. However, economically feasible deposits are rare, and the actual challenge lies in the intricate process required to separate them into materials necessary for manufacturing permanent magnets used across a range of crucial products.

China is responsible for approximately 60% of the global production of rare earth ores, but that share increases to 90% when it comes to processed rare earths and magnet manufacturing.

Extraction Process

Initially, ore is mined from open pits or underground locations, crushed, and transported to a processing facility typically situated close to the mine.

The ore contains a minor portion of rare earths, and other minerals are eliminated using flotation, magnetic, or electrostatic processes to yield a mixed concentrate consisting of about 60% to 70% rare earths.

Some operations also generate rare earth concentrates as byproducts from mining waste or from extracting other metals like mineral sands or iron ore.

Handling Radioactivity

Certain ores, such as monazite, require additional processing to eliminate radioactive thorium or uranium, often utilizing acid in the procedure.

Separation

The separation of individual rare earth elements is one of the most challenging phases. The initial separation technology was pioneered in U.S. government research facilities after World War II.

This separation can be achieved through ion-exchange technology or solvents such as ammonia and hydrochloric acid; however, some of these chemicals generate toxic waste that poses health risks.

Light and heavy rare earths must undergo distinct separation processes to extract each individual element.

Although newer, more eco-friendly methods are currently in development, they have yet to become mainstream.

Metals and Alloys

After separation, rare earth oxides are converted into metals through electrolysis.

The most common types of permanent magnets incorporate rare earth elements neodymium and praseodymium along with iron and boron, which are melted together in a vacuum induction furnace to create an alloy. Rare earth elements dysprosium and terbium are frequently added to enhance the magnet’s heat resistance.

Magnet Production

The resulting alloy ingots are then milled into micron-sized powder in a nitrogen-argon atmosphere, followed by a high-temperature and pressure process known as “sintering” before being shaped into final magnets.