Processing Is Key Element in US Rare-Earth Woes| Rare Earths

Bokan Mountain in Southeast Alaska is the proposed site of a heavy rare earth element mine.

(Image credit: Susan Karl, USGS)

Red state or blue state, liberal or libertarian, Americans share an addiction to rare-earth elements imported from China.

Green technologies such as electric cars, wind turbines, solar panels and fluorescent light bulbs rely on rare-earth metals. The military depends on rare earths for guided missile systems, satellites and unmanned drones. NASA's spacecraft carry powerful rare earth magnets to Mars and outer space. The magnets also miniaturized iPads, computers and high-tech headphones.

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A few years ago, China showed its power, and cut the supply of rare earths to a trickle. The move sent the United States and other countries scrambling to end their reliance on China. Prices soared, drawing new investors and mining companies into the rare earth market. Now, the United States has one new mine nearly finished and two more in the permitting stages. But the crucial element in escaping China's rare-earth rule isn't new mines, it's rebuilding the expertise and infrastructure to process the finicky metals, experts say.

In 2010, China spiked the cost of rare-earth elements when it started restricting exports and charging foreign companies higher prices. The price bubble sparked a worldwide frenzy to escape China's control. A new Australian-owned processing plant just opened in Malaysia. Others are planned in Canada, Europe and Africa. Several companies are also trying to develop an American supply for rare earths, some with support from the Department of Defense. [Infographic: Energy-Critical Elements to Watch]

In the United States, California's Mountain Pass mine reopened in 2010 and is expected to start producing light rare-earth elements this year. The mine was once the world's biggest producers of rare earths, but shut down in 2002 because of environmental problems and falling prices. Another mine is proposed in Wyoming, by Canadian company Rare Element Resources, but faces opposition from local residents.

One of the biggest rare-earth gambles is at Alaska's Bokan Mountain. Once mined for uranium, the granite peak on Prince of Wales Island contains rich veins of the harder-to-find heavy rare-earth elements. The project has strong support from Alaska's legislature and from nearby communities. A Canadian company plans to extract the ore and transform it into oxides with a custom-built processing plant. Therein lies the challenge.

Despite their name, rare earths are actually common in Earth's crust, though in low concentrations. The moniker is a holdover from the 19th century, when researchers discovered the oddly named elements in rarely found minerals. The 17 elements share a close affinity, with similar chemical properties and atomic weights. Bokan Mountain is one of the few spots on Earth with a bounty of heavy rare-earth elements, which have higher atomic weights. It's especially elevated in yttrium, which appears in everything from cubic zirconia and car pollution sensors to lasers, rockets and jet engines.

Because rare earths are often all mixed together in one rock, separating the heavy rare earths usually requires removing the lighter ones first. This is typically done with a series of chemical tanks and solvents. Plus, there's the radioactive uranium to dispose of. But mine owner Ucore says it has a new solid-extraction technology that greatly simplifies this process. The technique relies on nanotechnology to remove impurities and concentrate the heavy rare earths into oxides, according to Ucore. The Department of Defense funded Ucore's ore extraction research with a contract in October 2012.

The USGS also has projects exploring the geology of other rare-earth deposits. Since 2010, the House of Representatives has introduced legislation to curb mining regulations and fund rare-earth research and development, which have yet to pass the Senate. Recycling of rare-earth metals, which is not always made possible with high-tech gadgetry, is another way to reduce dependency on China's supply. Earlier this year, the Department of Defense recommended stockpiling $120 million of critical heavy rare-earth elements. But industry experts say money would be better spent on building American expertise and infrastructure in processing rare earths. [The Common Elements of Innovation]

Becky Oskin covers Earth science, climate change and space, as well as general science topics. Becky was a science reporter at Live Science and The Pasadena Star-News; she has freelanced for New Scientist and the American Institute of Physics. She earned a master's degree in geology from Caltech, a bachelor's degree from Washington State University, and a graduate certificate in science writing from the University of California, Santa Cruz.