As critical components for energy and defense technologies, the U.S. rare earth element (REE) ore reserves are estimated at ~13 million tons, but domestic production is currently limited to one operational mine residing on high-grade ore deposits in Mountain Pass, CA. While low-grade REE deposits are abundant, high-grade American REE deposits are sparse. Meanwhile, hazardous REE-containing tailings pile up at the economic and environmental cost, and it is estimated that REE value locked within e.g., red mud, is $796 per ton. However, such low-grade deposits or mining tailings are challenging to access because REEs are usually locked within a mineral matrix, typically iron oxide, that renders the ore intractable to mechanical or chemical separation. Here, we propose a process for recovering REEs from low-grade deposits and tailings by electro-metallurgically removing iron oxide, hydro-metallurgically removing aluminum salt, and subsequent separating insoluble rare earth oxides. Our strategy produces not only refinable REEs concentrates but also emissions-free iron metal and supplementary cementitious materials as co-products for decarbonizing steel and cement industries, respectively. By addressing the economic and environmental challenges associated with low-grade REE deposits and mining tailings, our electrochemical approach offers a sustainable pathway for unlocking the potential of domestic rare earth resources.
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