Aclara HREE separation plant anchors US heavy rare earth strategy

Aclara

Aclara HREE separation plant plans to reshape the US heavy rare earths supply chain by targeting dysprosium and terbium for EVs. The Aclara HREE separation plant in Louisiana will draw feed from ionic clay deposits in Brazil and Chile. As a result, the Aclara HREE separation plant positions the US to cut reliance on Chinese-controlled heavy rare earths.

Louisiana HREE hub to cover most US dysprosium and terbium demand

Aclara will invest $277mn in a Louisiana heavy rare earths separation facility focused on dysprosium, terbium and NdPr oxides. The company targets completion in 2027 and aims to supply more than 75pc of US dysprosium and terbium demand for EVs by 2028. This volume would materially shift US sourcing patterns for critical magnet materials.

The project benefits from approximately $46.4mn in state tax incentives and grants, underlining Louisiana’s push to attract strategic materials investments. Meanwhile, Aclara plans to integrate the separation plant with a future metals and alloys facility on the same site. This integrated footprint could support a mine-to-magnet pathway once downstream alloying and magnet projects materialise.

Ionic clay deposits in Brazil and Chile underpin feedstock security

Aclara will supply the Louisiana plant with feed from two ionic clay deposits located in Brazil and Chile. These deposits are expected to be operational in 2028, slightly lagging the HREE plant start-up. The company targets annual production of about 200t of dysprosium, 30t of terbium and 1,400t of separated neodymium-praseodymium oxide.

In Brazil, Aclara has already started de-risking its flowsheet through pilot operations. The Carina Project pilot plant in Goiania began running in April and produced its first rare earths concentrate in June. The firm also expects up to $5mn in support from the US International Development Finance Corporation, signalling strong strategic interest from Washington. Together, the Louisiana plant and South American deposits outline a multi-node HREE supply chain geared to long-term EV and magnet demand.

US HREE separation plant sits at the heart of magnet supply realignment

Aclara’s US HREE separation plant joins a growing list of projects aimed at diversifying global heavy rare earths supply. However, few projects are configured to supply such a large share of the domestic dysprosium and terbium market. If timelines hold, Louisiana could become a cornerstone hub feeding US and allied magnet manufacturers before the end of the decade.

At the same time, building metals and alloys capacity on-site raises the prospect of deeper value capture within US borders. Therefore, the project’s success will be judged not only on tonnage but also on how effectively it links to magnet makers and OEMs. For automakers and defense contractors, locking in offtake from a US-based HREE separation plant may become a strategic priority.

The Metalnomist Commentary

Aclara’s HREE separation investment in Louisiana illustrates how quickly the heavy rare earth landscape is evolving under geopolitical pressure. The combination of ionic clay feed from Brazil and Chile with US separation capacity provides a diversified platform that investors and OEMs will watch closely. If execution matches ambition, this project could become a reference model for trans-regional critical mineral partnerships anchored in US downstream processing.