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Research on Rare Earth Elements

The Anchor House, Inc.

The GAO Speaks! (Why We Should All Listen)

April 14th, 2010

By Clint Cox

Today the US Government Accountability Office (GAO) publicly released its eagerly anticipated report entitled Rare Earth Materials in the Defense Supply Chain”.

Although there are no colossal revelations in the report, it is a fascinating read and shows the thorough nature of the GAO. In putting together the report, they contacted:

  • Department of the Interior
  • Department of Commerce
  • Department of Energy
  • Department of Defense
  • Various members of industry and academia

They go through a number of issues in the report, including a look at key rare earth processing steps (emphasis mine):

  • Mining rare earth ore from the mineral deposit
  • Separating the rare earth ore into individual rare earth oxides
  • Refining the rare earth oxides into metals with different purity levels
  • Forming the metals into rare earth alloys
  • Manufacturing the alloys into components, such as permanent magnets, used in defense and commercial applications

When simplified, the above list gives us the following stages of rare earth products:

  • Ore
  • Oxides
  • Metals
  • Alloys
  • Components

There are different players involved at each of the above stages, and many smaller stages between—so the complexity of what the GAO is undertaking here (an understanding of REEs in the defense supply chain) is no small endeavor.

When looking at rebuilding the supply chain, the following statement is made:

Based on industry estimates, rebuilding a U.S. rare earth supply chain may take up to 15 years and is dependent on several factors, including securing capital investments in processing infrastructure, developing new technologies, and acquiring patents, which are currently held by international companies.

15 years seems optimistic to me, but I’m all for rolling up some sleeves and getting to work!

It is also clear from this report that other agencies have recently researched, or  are currently researching the rare earth issue, including:

  1. DOD study to be completed September 2010
  2. Air Force’s Materials and Manufacturing Directorate internal report 2003
  3. Army’s Armament Research Center informal efforts to understand dependency on REEs
  4. Naval Surface Warfare Center informal efforts to understand dependency on REEs
  5. Navy considered funding Mountain Pass in 2006 under Title III program
  6. Department of Commerce roundtable
  7. The Office of Science and Technology Policy in the Executive Office of the President interagency meeting recently
  8. Department of Energy R&D projects
  9. Department of Energy strategic plan for REEs being developed

This report is critical because it outlines the efforts underway by our government to understand important topics surrounding the rare earths.  The government is a powerful force, and it can have a profound impact on the industry as a whole.  That there is so much interest from the government is phenomenal — how it plays out will be worth watching!

Now we wait for everyone’s response!  Like a great soap opera – how will the media respond?  How will the different agencies work together?  Will this affect the current legislation being considered by Congress (HR4866)?

If you’ve missed the rare earth show up until now — there still may be plenty of action to come!

Conference Cornucopia: Part 2, TREM

April 13th, 2010

By Clint Cox

It was stated at the Technology and Rare Earth Metals for National Security and Clean Energy (TREM) Conference in Washington DC on March 17-18, that there are two modes of energy policy in Washington:

  1. Complacency
  2. Panic!!!

This may prove true for the rare earths as well. Please don’t misunderstand, the Conference was filled with intelligent and fantastic conversations, but the mood has changed and it is now clear that this issue is beginning to gain some favor in Washington DC.

TREM_sign

Now for some highlights!

Dudley Kingsnorth of IMCOA had plenty of insight to share with the audience. At one point, he spoke about the importance of the pilot plant phase for rare earth exploration companies. Pilot plants are built in order to establish the flow sheet and according to Kingsnorth are required to:

  • Generate samples for customer approval as basis for sales contracts
  • Demonstrate technical viability
  • Provide data for bankable feasibility study
  • Generate data for environmental impact statement

The real shocker that Kingsnorth revealed didn’t seem to garner much fanfare, but is critical to this discussion and should change the tenor of discussion: Rest of world (ROW) demand has been lower than exports since 2005. In other words, all the hype about China shutting off the rest of the world isn’t necessarily backed by the facts. At this point, the Chinese export quotas have easily accommodated the demand by the rest of the world for material outside of China. This opens up other discussions, but may change the character of some of the arguments being made.

Constantine Karayannopoulos of Neo Material Technologies Inc. offered some great perspective as president and CEO of a company that operates facilities within China. He pointed out that China has one strategy in the rare earth business – employment growth. Provincial governments are judged on job growth.

His final points for the audience were:

  • Reduce red tape
  • Research & development (R&D) are indispensable

Paul Werbos, the Research Program Director of the National Science Foundation, reinforced Karayannopoulos’ last point. Werbos emphasized that R&D can have a dramatic effect, and he pointed out that new cross-disciplinary research might maximize the probability of breakthrough designs.

Gareth Hatch of Dexter Magnetic Technologies explained some of the issues surrounding new wind turbine capacity and its demand for neodymium (Nd) oxide moving forward. For instance, he pointed out that demand for Nd in wind turbines might reach 2,950 tonnes by 2013.

Peter Dent of Electron Energy Corporation stated that samarium-cobalt is a $300 million industry and that ferrites (magnets based on iron technology) still retain a 90% share of the entire market.

Sheeraz Haji of Cleantech Group LLC spoke of the revolution in financing for green technologies, as the percentage of venture capital that goes into green tech has risen from less than 2% in 2003 to a predicted 27% in 2010. Wow! That is significant. He pointed out that 72% of global cleantech investment is happening in Asia / China. This is very startling.

Haji also stated that Walmart is demanding energy usage, water usage, and waste data from suppliers.

Steven Duclos of General Electric Global Research had some fantastic perspective on REEs and strategic materials. He showed a criticality diagram which displayed the supply and price risk associated with individual elements and their potential impact on General Electric.

He is very aware of the effect of supply issues, and suggested that parallel paths must always be taken because you don’t know which path will be successful.

One of the great charts that he used showed the elements used to make incandescent lamps, fluorescent lamps, white LEDs, and White OLEDs. The surprise? No rare earths at all in the white OLEDs.

David Sandalow, the US Assistant Energy Secretary for Policy and International Affairs, had much to say regarding rare earths.

“It goes without saying that diversified sources of supply are important for any strategic material. So too are substitutes and strategies for re-use and recycling. If rare earth metals are going to play an increasing role in our economy, we need to pursue those strategies. And there’s every reason to believe that rare earth metals could play an increasing role in the global economy as the world transitions to clean energy.”

To address the availability of REEs and other strategic materials, Sandalow suggested a three-part approach:

  1. Globalize supply chains for strategic materials
  2. Develop substitutes
  3. Promote recycling, re-use and more efficient use

He also announced the proposed development of a strategic plan:

“To help address these concerns, I am today announcing that the Department of Energy will develop its first-ever strategic plan for addressing the role of rare earth and other strategic materials in clean energy technologies. The plan will apply the approaches described above and draw on the strengths of the Department in technology innovation. We will build on work on these topics already underway, including in DOE’s national labs, and work closely with colleagues from other agencies throughout the U.S. government. We will solicit broad public input, including from the stakeholders and experts here in this room.”

Sandalow mentioned that there was lots of work underway already, and that there were no firm timelines yet in place.

His talk was well received by the audience, and we look forward to hearing more.

Full Metal Jacket, a panel discussing rare earths from the Pentagon’s perspective, addressed the complexity of assessing the both the Big Picture and specific needs. Some of the issues raised during the panel were:

  • Looking at both civilian and military uses for REEs
  • The DOD doesn’t buy rare earths – it buys tanks, ships, guns, etc.
  • There is no national strategy on REEs thus far
  • They are looking at cradle to grave issues with materials

Mark Smith of Molycorp Minerals pointed out on the producer’s panel that it is hard to find qualified people with REE skills.

Congressman Mike Coffman spoke about HR4866 – a new rare earth bill that he had just introduced the day before. From the bill:

A bill to reestablish a competitive domestic rare earths minerals production industry; a domestic rare earth processing, refining, purification, and metals production industry; a domestic rare earth metals alloying industry; and a domestic rare earth based magnet production industry and supply chain in the United States.

Many people in the audience have been watching this closely, so it was great to have Congressman Coffman talk about this with us in person.

Cindy Hurst gave a good talk on the history of China and the rare earth industry. She has written a paper entitled “China’s Rare Earth Elements Industry: What Can the West Learn?”.

We spent the afternoon of the second day in breakout sessions that were both fascinating and illuminating, as this diverse group of participants was able to discuss and debate these issues together.

Special thanks to Dr. Gal Luft and Yaron Vorona for putting together one of the best rare earths conferences I’ve been to!

Conference Conucopia: Part 1

April 2nd, 2010

By Clint Cox

My first rare earth conference of the year was an investment bank conference in Australia in Early February – since then it has been an endless barrage of rare earth conference mania!

The SME, Phoenix, February 28-March 3

The Society for Mining, Metallurgy & Exploration (SME) had three technical sessions that included the REEs—one session on March 1, and two on March 3.  At the conference, there were almost 5000 attendees and over 600 booths. The sessions were well attended, and there was also a cocktail party for the rare earth community.

SME_sign

Here is a brief look at the three sessions:

Geology VI: Strategic Minerals and Materials: Harder, Better, Faster, Stronger.

James Hedrick’s talk was entitled “Rare Earths in Defense Applications”.

Cheryl Seeger gave a talk about REEs Missouri called “Mineralogy and Geology of the Southeast Missouri Iron Metallogenic Province“.

Geology IV: Rare Earths: Extraction, Application and the Market.

Ed McNew presented an excellent talk on processing named, Mineralogical Considerations in the Processing of Rare Earths Ores to Concentrates.  This talk was chock full of images that showed quite clearly some of the issues surrounding the processing of the REEs. He also discussed many of the instruments used in identifying minerals and their critical properties for processing.

Les Heymann gave one of the best talks I have ever heard on evaluating rare earth deposits in “The Valuation of Rare Earth Deposits”.  He described the difference between Light Rare Earth Element (LREE) projects and Heavy Rare Earth Element (HREE) projects, and the issues of balance that pertain to both. He concluded that NPV is a good way to evaluate REE deposits.

Stan Trout gave a really informative talk entitled “Rare Earth Permanent Magnets: Raw Materials, Magnets and Opportunities”. Trout is one of the leading experts in the field,  but he is also a professor so he has gotten very good at communicating the complexities of the subject in a fun and very informative fashion.

Dudley Kingsnorth was unable to attend the conference, but he graciously allowed me to give his talk, “Rare Earths: Facing New Challenges in the New Decade”, in his absence.  As usual, Kingsnorth’s presentation was replete with fantastic charts—including an update of the legendary “Dudley Chart”. He also had several slides explaining the 10 steps to commercial rare earths production.

Geology V: Rare Earths: Geology & Exploration

Don Ranta presented Exploration and Evaluation of the Bear Lodge Rare-Earth Project, Wyoming”, giving the audience a useful update on progress being made at Bear Lodge in Wyoming.

Harmen Keyser did an excellent job detailing the rare earth project at Bokan Mountain in his talk, The Bokan Mountain REE-U Deposit, Prince of Wales Island, Alaska”.

Dr. Anthony N. Mariano gave an illuminating two-part presentation entitled “REE Deposits on a World Level – Real and Potential: Parts 1 & 2”.  In this talk he touched briefly on historic resources and minerals, as well as potential for future deposits around the world.

In addition to these sessions on REEs, there were also several other talks given on rare earths in other sessions, including two by Mark Smith of Molycorp Minerals LLC, and one by Jim Kennedy of Wings Enterprises.

A link to some of the presentations is found here:

http://www.smenet.org/rareEarthsProject/

PDAC, Toronto, March 7-10

For the first time I have been to the PDAC, the weather in Toronto was actually quite nice in March!  There were about 22,000 attendees and about 1000 exhibitors.  The size of this conference is staggering.

PDAC_sign

Two years ago I wandered the exhibit halls trying to find anyone who cared about rare earths.  I didn’t find many.  This year “rare earth” was the watchword.  What a difference!

Rare earths arrived at the PDAC in style with two cocktail parties (each attended by over 100 people), one power breakfast (standing room only), one exchange forum session, and one technical session (jam-packed, with folks waiting outside).

The number of junior exploration companies looking at this space has exploded.  Boom.  Seriously — there are now hundreds of hopefuls, but very few who know what they are doing.  Rare earth geologists (the very few that there are) are now experiencing celebrity status.

The hooplah is overshadowed by hype, but the hype is most certainly bypassed by the ballyhoo!

How long this will last is anybody’s guess, but it’s fairly entertaining for now.

More to come on the TREM in Washington—lots happened here, so I want to spend a little more time on it.