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.

Aclara HREE Separation Plant Gains $21mn Louisiana Tax Incentive

Aclara

Aclara HREE separation plant plans in Louisiana have gained a significant boost after the state approved an estimated $21mn property tax exemption for the Canadian rare earth developer. The incentive supports Aclara’s effort to build US separation capacity for strategically important heavy rare earth elements.

Aclara HREE separation plant development is aimed at converting mixed rare earth carbonates from Chile and Brazil into separated oxides. Planned products include dysprosium, terbium, yttrium, gadolinium and samarium, alongside neodymium-praseodymium.

Aclara HREE separation plant capacity is particularly important because heavy rare earth separation remains one of the most concentrated parts of the global supply chain. Dysprosium and terbium are critical for high-performance permanent magnets used in defence, aerospace, electric vehicles and industrial motors.

The company aims to break ground in the fourth quarter of 2026 while continuing engineering, permitting and financing work.

Tax Relief Strengthens Louisiana Project Economics

Louisiana approved an 80% exemption from ad valorem property taxes under the state's Industrial Tax Exemption Program. The initial benefit will run for five years.

Aclara expects the exemption to reduce property tax costs by around $4.2mn annually, equivalent to $20.8mn over the initial period. The incentive can also be renewed for another five years.

This support improves the economics of a project that must compete with established Chinese rare earth separation capacity. Heavy rare earth processing requires complex chemistry, specialised equipment and tight product quality control.

The planned facility will have annual production targets of 1,131t of neodymium-praseodymium, 148t of dysprosium and 25t of terbium.

Those heavy rare earth volumes are small compared with bulk commodities but strategically meaningful. Dysprosium and terbium are used in relatively small quantities to improve permanent magnet performance at elevated temperatures.

This makes even modest new western capacity important for defence, automotive and advanced manufacturing customers seeking diversified supply.

Chile and Brazil Feedstocks Link to US Processing

Aclara plans to feed the Louisiana plant with mixed rare earth carbonates produced from its ionic clay resources in South America.

The company’s upstream portfolio includes the Carina project in Brazil and the Penco project in Chile. This creates a potential supply chain linking Latin American mineral resources with downstream separation in the US.

That structure is strategically important. The US needs more rare earth separation capacity, but domestic processing facilities also need reliable feedstock sources outside China.

Aclara’s model addresses both sides by combining South American ionic clay resources with a US-based refining platform.

However, the company still faces execution risk. Engineering, permitting, financing and construction must all advance before the planned plant can move into production.

If successful, the Louisiana facility could become an important source of separated heavy rare earth oxides and strengthen the emerging non-China magnet materials supply chain.

The Metalnomist Commentary

Aclara’s tax incentive shows that US rare earth policy is increasingly moving from mine support toward midstream separation. The real strategic value lies in connecting South American HREE resources with US processing capacity for dysprosium and terbium.

Aclara Rare Earth Oxides Plan Links Brazil Mining to US Separation

aclara

Aclara rare earth oxides production plans have been reaffirmed for the Carina project in Brazil, strengthening the company’s role in the emerging Americas rare earth supply chain. The Brazilian rare earth producer expects to produce more than 4,300 t/yr of rare earth oxides from 2028.

Aclara rare earth oxides output is expected to average 4,378 t/yr contained in mixed rare earth concentrate. The planned product mix includes 1,191 t/yr of neodymium-praseodymium, 156 t/yr of dysprosium and 27 t/yr of terbium.

Aclara rare earth oxides are strategically important because NdPr, dysprosium and terbium are key inputs for high-performance permanent magnets. These magnets are used in electric vehicles, wind turbines, robotics, defence systems and advanced industrial motors.

The Carina project is expected to have an 18-year mine life. Production costs are estimated at $29.20/kg of rare earth oxide produced, giving investors and customers a clearer basis for assessing the project’s long-term competitiveness.

Carina Project Adds Heavy Rare Earths to the Americas Supply Base

The Carina project’s value is not limited to light rare earths. Its mixed rare earth concentrate also contains several heavy rare earth elements that are difficult to secure outside China-linked supply chains.

Aclara expects annual output to include 173 t of samarium, 176 t of gadolinium, 10 t of lutetium and 1,160 t of yttrium. These materials add strategic depth to the project because heavy rare earth supply remains highly concentrated and increasingly sensitive to export controls.

Dysprosium and terbium are especially important for magnet performance. They improve heat resistance and magnetic stability in demanding applications such as EV traction motors, wind turbine generators and defence electronics.

The project therefore fits a wider western effort to build alternative rare earth supply chains. Brazil offers mineral potential, while the US provides downstream policy support and processing infrastructure incentives.

Construction at Carina is scheduled to begin in the third quarter of 2026. Initial output is expected in the second half of 2028, followed by ramp-up in 2029.

Louisiana Separation Plan Builds Downstream Magnet Chain

Aclara plans to send material from Carina to Louisiana for separation and processing. The US site will produce rare earth metals and alloys, moving the project beyond mine supply into downstream magnet material preparation.

This structure matters because rare earth security depends on more than mining. Mixed rare earth concentrate must be separated, refined, converted into metals and alloyed before it can support permanent magnet production.

The Louisiana processing route could therefore create a more integrated Brazil-US rare earth chain. It links Brazilian ionic clay-style rare earth resources with US separation, metal and alloy capacity.

Public-sector support strengthens the project’s strategic profile. The US International Development Finance Corporation provided $5mn for Carina’s development, while Louisiana granted $46mn in tax incentives to accelerate the separation project.

For western magnet manufacturers, Aclara’s model offers potential supply diversification. The company could provide NdPr, dysprosium and terbium units into a market where downstream users are actively seeking non-China material.

However, execution remains critical. The project must move through construction, commissioning, ramp-up and qualification before it can become a reliable supply source for magnet makers and strategic customers.

The Metalnomist Commentary

Aclara’s plan shows that rare earth competitiveness now depends on linking mine output with separation and metal conversion. The Brazil-Louisiana route could become strategically important if it delivers heavy rare earth volumes into the Americas magnet supply chain.

Element 25 Butcherbird Manganese Expansion Gains Funding for Battery Supply Chain

Element 25

Element 25 Butcherbird manganese expansion has moved forward after the Australian metals producer raised $18mn in equity to support the next phase of mine growth. The funding will help expand manganese concentrate output from the Butcherbird mine in Western Australia.

The project is expected to triple Butcherbird’s manganese concentrate production to 1.1mn t/yr from 365,000 t/yr. Full mechanical completion and commissioning are expected in the first quarter of 2027.

Element 25 Butcherbird manganese expansion is strategically important because the mine will supply feedstock for the company’s planned battery-grade manganese sulphate refinery in Louisiana. That project links Australian ore supply with US battery materials processing.

The expansion also strengthens Element 25’s role in the electric vehicle supply chain. The company already has offtake agreements with General Motors and Stellantis, giving the project direct exposure to automaker demand for non-China battery materials.

Butcherbird Expansion Builds Manganese Feedstock Scale

Western Australia’s state government approved the Butcherbird expansion in March 2025. The mine is expected to operate for at least 18 years, giving Element 25 a long-term feedstock platform.

The planned increase to 1.1mn t/yr of manganese concentrate would materially change the scale of the operation. Higher concentrate output should support downstream conversion into battery-grade manganese sulphate while also leaving room for sales into traditional steel markets.

Manganese remains a key steelmaking input because it improves strength and toughness. Element 25 plans to sell excess concentrate to steelmakers, creating a secondary demand channel outside batteries.

However, the main strategic value is in batteries. Manganese is increasingly important for lithium-ion battery chemistries as automakers seek lower-cost, more secure and less cobalt-dependent cathode materials.

Louisiana Refinery Links Australia to US Battery Materials Policy

Element 25’s manganese concentrate will mainly feed its battery-grade high-purity manganese sulphate monohydrate facility in Louisiana. The refinery is planned for 135,000 t/yr of production capacity.

The US government backed the Louisiana refinery with a $166mn grant in January last year. This support reflects Washington’s effort to build domestic processing capacity for battery materials and reduce reliance on China-controlled supply chains.

The Australian government also opened a A$50mn loan package in June to support the Butcherbird expansion. Together, the US and Australian support show how allied governments are trying to connect mining, refining and EV manufacturing supply chains.

Element 25 Butcherbird manganese expansion therefore fits a broader industrial strategy. Australia provides the resource base, while the US builds refining capacity closer to automakers and battery manufacturers.

The project’s success will depend on execution at both ends of the chain. Butcherbird must deliver concentrate at scale, while Louisiana must convert that material into battery-grade sulphate that meets customer specifications.

The Metalnomist Commentary

Element 25’s project shows how manganese is moving from a steelmaking material into a strategic battery supply input. The key challenge will be proving that mine expansion and US chemical refining can scale together on the timeline automakers require.

upply to VAC supports US magnet manufacturing

Ucore rare earth

Ucore rare earth supply to VAC will underpin a new US magnet manufacturing hub in South Carolina. The Ucore rare earth supply to VAC centres on separated oxides from Ucore’s Louisiana and Ontario facilities for eVAC’s Sumter County plant. As a result, the Ucore rare earth supply to VAC strengthens a non-Chinese supply chain for critical magnet materials.

Building a North American rare earth magnet value chain

Ucore will supply neodymium, praseodymium, terbium, dysprosium, samarium and gadolinium oxides to VAC and its subsidiary eVAC. These separated rare earth oxides will feed eVAC’s new permanent magnet facility in Sumter County, South Carolina. The plant targets high-performance magnet demand from EVs, wind turbines and defense systems.

The deal leverages Ucore’s planned Louisiana Strategic Metals Complex and its Commercial Demonstration Facility in Ontario. These assets aim to become key separation hubs for non-Chinese mixed rare earth concentrates. VAC, a leading German magnet producer, gains secure North American feedstock close to downstream customers.

Feedstock security through diversified offtake agreements

Ucore has been assembling a diversified pipeline of rare earth feedstock ahead of Louisiana SMC commissioning. It previously signed an agreement with Australia’s Metallium to potentially secure mixed rare earth concentrate. Ucore also has a non-binding offtake with US developer Critical Metals for 10,000 t/yr of rare earth concentrate.

These arrangements reduce single-source risk and improve resilience against geopolitical disruptions. Meanwhile, VAC’s US investment aligns with government efforts to localise permanent magnet production for EV and defense supply chains. Both parties now have nine months to finalise long-term commercial terms, including volumes, pricing structures and potential take-or-pay elements.

The Metalnomist Commentary

This Ucore–VAC alignment is a textbook example of how midstream separation and downstream magnet capacity are finally linking up in North America. The success of Louisiana SMC and eVAC’s Sumter County plant will be a key test of whether non-Chinese rare earth supply chains can scale fast enough to meet accelerating magnet demand.

Atalco to boost US alumina, gallium production

Atalco

Atalco to boost US alumina, gallium production after securing $450mn to restart capacity and add new critical minerals output. Atalco to boost US alumina, gallium production by restoring its Louisiana refinery to nameplate levels and installing a new primary gallium circuit. As a result, Atalco to boost US alumina, gallium production as Washington pushes harder for resilient domestic supply chains.

Atlantic Alumina will direct the funding to its Gramercy, Louisiana, refining site to return alumina production to 1.2mn t/yr. The company will also build a 50 t/yr gallium production circuit and upgrade mineral processing and power generation capability. Meanwhile, the company has not provided a public project timeline or detailed restoration plan.

Why alumina and gallium now sit in the same national security basket

Atalco to boost US alumina, gallium production because both materials matter for defense, aerospace, and semiconductors. The US has limited domestic alumina output relative to demand and no primary gallium production, which creates exposure during trade disruptions. Therefore, a restart at Gramercy could strengthen supply assurance for downstream aluminium and high-tech manufacturing.

Atalco operates the only US alumina refinery, which makes the site strategically important. The refinery processes bauxite, and gallium can be recovered as a by-product stream in alumina production. However, recovery performance and unit economics will depend on bauxite chemistry, circuit design, and sustained operating rates.

Funding structure and supply chain linkages signal a broader buildout

Atalco to boost US alumina, gallium production with a blended finance structure that mixes public and private capital. The Department of Defense is providing $150mn through an industrial base program, while the remaining $300mn comes from a private capital sponsor linked to Concord Resources. As a result, the project reflects a growing model where government anchors projects that private markets might otherwise delay.

Feedstock sourcing also matters for delivery certainty. Atalco receives bauxite from Jamaica through a joint venture, which supports continuity of supply while the US rebuilds midstream capacity. Meanwhile, parallel Louisiana efforts to recover gallium from red mud highlight a wider push to extract critical minerals from industrial waste streams, not just primary mines.

The Metalnomist Commentary

This project is a strategic restart with a dual benefit: aluminium supply resilience and new domestic gallium output. However, the market will judge success on execution speed and reliable gallium recoveries at scale. If Gramercy stabilizes operations, it could become a template for midstream critical minerals re-industrialization.

Ucore Rare Earth Supply Partnership Expands With Sumitomo

Ucore Rare Earth

Ucore rare earth supply strategy is gaining a major commercial partner after Ucore Rare Metals formed a strategic collaboration with Sumitomo Corporation of Americas. The agreement will support feedstock procurement, separated rare earth sales and market access in Japan.

Ucore rare earth supply development will center on the planned Louisiana Strategic Metals Complex, where the company intends to process rare earth feedstock into separated products. Sumitomo will help secure suitable raw materials and develop offtake channels.

Ucore rare earth supply plans are particularly focused on selected middle and heavy rare earth elements used in high-performance permanent magnets and advanced materials. These elements remain among the most strategically constrained parts of the global rare earth supply chain.

The partnership also strengthens links between North American processing and Japanese industrial demand while preserving material for additional processing in the US and allied markets.

Sumitomo Adds Feedstock and Japanese Market Access

Sumitomo will act as a distribution partner for designated separated rare earth products sold into selected Japanese customer segments and other industrial applications.

This gives Ucore access to an established trading network with experience across rare earth procurement, distribution and downstream customer relationships.

The collaboration is significant because building separation capacity alone does not guarantee commercial success. Rare earth refiners need reliable feedstock on the upstream side and qualified buyers for separated oxides on the downstream side.

Sumitomo already has experience building such supply chains. The company became the exclusive distributor of neodymium-praseodymium oxide produced by MP Materials in 2023.

It also established Summit Atom Rare Earth Company in Kazakhstan to produce rare earth materials containing dysprosium and neodymium.

That platform now connects African feedstock, Kazakh processing and Japanese technology through relationships with Lindian Resources and Shin-Etsu Chemical.

For Ucore, Sumitomo therefore brings more than distribution capability. It brings an existing international network spanning mining, separation and magnet-related markets.

Heavy Rare Earths Strengthen Allied Supply Chain Strategy

The partnership's focus on middle and heavy rare earths is strategically important because these materials remain highly concentrated in Chinese supply chains.

Dysprosium and other heavy rare earths are critical for permanent magnets that must maintain performance at elevated temperatures. They are widely used in electric vehicles, defence systems, aerospace and advanced industrial equipment.

Ucore's Louisiana facility is intended to provide an alternative separation route for these materials in North America.

Securing feedstock from multiple jurisdictions will be essential. A processing facility without diversified raw material supply can simply replace one dependency with another.

The Sumitomo partnership addresses that risk by combining sourcing, processing and offtake development across allied markets.

It also reflects a broader shift in rare earth strategy. Governments and companies are increasingly building interconnected supply chains across the US, Japan, Australia, Africa and Central Asia rather than relying on individual national projects.

If Ucore successfully commissions the Louisiana complex, Sumitomo's commercial network could help accelerate customer qualification and reduce market-entry risk.

The Metalnomist Commentary

Rare earth security increasingly depends on linking mines, separation plants and customers across multiple allied countries. Ucore's partnership with Sumitomo is strategically valuable because it addresses both sides of the processing bottleneck: feedstock supply and downstream market access.

Aclara REE Separation Pilot Plant Advances US Heavy Rare Earth Supply Chain

Aclara REE

Aclara REE separation pilot plant commissioning in Virginia marks an important step toward building a non-China rare earth processing route for heavy and light rare earth oxides. Chilean rare earths producer Aclara Resources has opened the pilot facility in Blacksburg as part of its strategy to create a vertically integrated rare earth supply chain.

The plant will process mixed rare earth carbonates sourced from Aclara’s ionic clay deposits in Brazil and Chile. This gives the company a route to connect South American rare earth resources with US-based separation technology and future downstream supply.

The Aclara REE separation pilot plant is designed to produce separated dysprosium, terbium, and neodymium-praseodymium. First light rare earth oxide output is scheduled for May 2026, while heavy rare earth oxide output is expected in August 2026.

Virginia Pilot Plant Targets Critical Magnet Materials

The Virginia facility matters because rare earth separation remains one of the most difficult and strategically sensitive parts of the supply chain. Mining or producing mixed carbonate is only the first step; the real value is created when individual rare earth oxides are separated to commercial specification.

Dysprosium and terbium are especially important because they are used to improve high-performance permanent magnets. These magnets support electric vehicles, wind turbines, robotics, defense systems, and advanced industrial equipment.

Neodymium-praseodymium is also central to magnet production. By targeting both light and heavy rare earth oxides, Aclara is positioning the pilot plant as a technical bridge between upstream ionic clay resources and downstream magnet material demand.

Louisiana Facility Could Scale Aclara’s US Processing Strategy

The Aclara REE separation pilot plant will support engineering, ramp-up, and process optimization for the company’s planned commercial separation facility in Louisiana. That project requires capital investment of $277 million and is scheduled to begin operations by mid-2028.

The collaboration with Virginia Tech and Argonne National Laboratory strengthens the technical base behind the project. It also aligns Aclara with US efforts to build domestic rare earth processing capacity for materials that remain heavily exposed to China-controlled supply chains.

For the market, the key question is whether Aclara can move from pilot output to reliable commercial-scale separation. If successful, the Louisiana facility could become a meaningful new processing node for dysprosium, terbium, and neodymium-praseodymium outside Asia.

The Metalnomist Commentary

Aclara’s Virginia pilot plant shows that rare earth supply security depends on separation technology, not only resource ownership. The company’s model also highlights a practical route for linking Latin American deposits with US processing capacity and strategic magnet demand.

Ucore Secures $18M DOD Grant to Expand U.S. Rare Earth Separation Plant

Ucore Rare Metals

Strategic Metals Complex to Process Key REEs by 2026

Ucore Rare Metals has received $18.4 million from the U.S. Department of Defense to expand its rare earth separation plant in Louisiana, significantly advancing domestic REE processing capabilities. The Focus Keyphrase "Ucore rare earth separation plant" reflects the facility’s rising strategic value amid efforts to reduce U.S. dependence on Chinese supply chains.

This funding increases a previous $4 million agreement with the U.S. Army Contracting Command and will support Phase II development of the Louisiana Strategic Metals Complex (SMC) in Alexandria. The plant aims to commercially separate six critical rare earth elements — including neodymium, praseodymium, and dysprosium — all of which are vital for defense and clean energy technologies.

Kingston Prototype Expansion and Commercial Scale-Up

The DOD grant also backs the expansion of Ucore’s REE separation prototype facility in Kingston, Ontario, enhancing the company’s technical foundation for scaling commercial operations. Together, the Louisiana and Ontario sites will form an integrated North American rare earth supply chain.

Ucore’s SMC facility will process both light and heavy rare earth oxides at commercial volumes. These include materials used in permanent magnets for electric vehicles, wind turbines, and military applications. The company plans to begin construction and initial production in the second half of 2026.

Strengthening U.S. Rare Earth Independence

This investment demonstrates the U.S. government’s commitment to de-risking critical mineral supply chains, especially in response to China's tightening export controls on rare earths. Ucore’s project is one of the few in North America capable of separating multiple rare earth elements at commercial scale.

The development aligns with national defense priorities and the Inflation Reduction Act’s push to localize materials essential to the energy transition and strategic manufacturing.

The Metalnomist Commentary

Ucore’s rare earth separation plant, backed by the Department of Defense, signals a decisive step toward reshoring high-value critical mineral processing. With construction slated for 2026, the SMC could become a cornerstone of U.S. rare earth independence in an increasingly geopolitically charged market.

Ucore–Critical Metals REE Offtake Deal Signals North American Processing Push

Ucore

Ucore–Critical Metals REE offtake deal secures Greenland feedstock for Ucore’s US processing plans. The Ucore–Critical Metals REE offtake deal covers 10,000t/yr of rare earth concentrate. The Ucore–Critical Metals REE offtake deal runs for ten years and targets US magnet supply chains.

Long-term feedstock from Greenland to Louisiana

Ucore will receive 10,000t/yr of REE concentrate from Tanbreez. That equals about 10% of Tanbreez’s initial output. The non-binding LOI sets a ten-year term. Ucore plans conversion at its Strategic Metals Complex in Alexandria, Louisiana. The complex will produce separated rare earth oxides from mixed carbonates. Initial volumes will run through Ucore’s commercial demo facility in Kingston, Ontario. This staged ramp reduces technical and logistics risk.

Financing, permitting, and industrial context

The Louisiana plant broke ground in May with federal and state backing. US DoD funding totals $18.4mn. Additional state support underpins site development. The agreement diversifies feedstock away from China-centric processing. Therefore, the deal aligns with US critical minerals policy. It also advances a North American heavy and light rare earth pathway. Timing still depends on Tanbreez’s execution and shipping cadence.

Ucore positions the complex as a mid-stream anchor. Meanwhile, OEMs seek reliable NdPr, Dy, and Tb oxide supply. Consistent feed should strengthen offtake terms downstream. As a result, magnet makers may gain qualification optionality in North America.

The Metalnomist Commentary

This LOI is strategically important, even if non-binding today. Watch for binding conversion, shipping schedules, and oxide qualification milestones. Execution at Tanbreez and Alexandria will determine real market impact.

Element 25 Secures $166M US Grant for High-Purity Manganese Plant

Element 25

Louisiana Refinery to Strengthen North American Battery Supply Chain

Element 25 (E25) has received a $166 million grant from the US Department of Energy (DOE) to develop its high-purity manganese sulphate monohydrate (HPMSM) refinery in Louisiana. The project, set to begin construction on April 1, 2025, will refine manganese concentrate from the Butcherbird mine in Western Australia. This initiative aligns with the US government’s $3 billion plan to boost domestic battery materials production, reducing reliance on Chinese supply chains.

Strategic Financing and Automaker Partnerships

The DOE grant supports a critical part of Element 25’s financing strategy, supplementing an $85 million loan from General Motors (GM) and a $30 million investment from Stellantis in 2023. Under these agreements, E25 will supply 32,500 t/yr of HPMSM to GM and 10,000 t/yr to Stellantis. These partnerships reflect automakers’ efforts to secure stable battery material supplies amid increasing demand for manganese-rich battery chemistries.

Rising Demand for Battery-Grade Manganese

In 2024, global HPMSM production reached 300,000 tonnes, but analysts forecast a 1.2-1.3 million t/yr supply deficit by 2034 due to surging EV battery demand. The Louisiana refinery positions Element 25 as a key supplier in the North American EV supply chain, addressing the growing need for high-purity manganese in lithium-ion battery cathodes.

Metallium flash joule heating partnership targets US gallium and scandium from red mud

Metallium

The Metallium ElementUSA partnership aims to unlock gallium and scandium supply inside the US. The companies will recover gallium and scandium recovery streams from alumina red mud in Louisiana. Therefore, the Metallium ElementUSA partnership positions red mud as a strategic critical minerals feedstock.

Metallium will deploy its flash joule heating technology at a demonstration facility ElementUSA is developing in Gramercy, Louisiana. The project targets gallium, scandium, and other critical minerals. Meanwhile, the work builds on growing pressure to diversify supply chains away from China.

DoD funding accelerates pilot work and scale-up options

US defense funding has moved the project into an implementation pathway. The US Department of Defense awarded $29.9mn to ElementUSA in November for the facility and early work in Texas. As a result, ElementUSA can move faster from concept to pilot operations.

ElementUSA also committed up to $10.1mn to help Metallium install flash joule heating units in Anahuac, Texas. The teams will run pilot-scale testing on red mud feedstock. However, the longer-term plan targets capacity ramp-up at the Gramercy site.

Red mud volumes create a large domestic feedstock base

Red mud availability anchors the economics of any recovery process. ElementUSA has up to 30mn tonnes of red mud under contract at the Gramercy alumina refinery. Therefore, the Metallium ElementUSA partnership can test at scale without sourcing constraints.

Gallium and scandium sit at the intersection of defense demand and supply risk. Both metals support advanced electronics, radar systems, and lightweight alloys. Meanwhile, recent Chinese export controls have tightened Western supply and elevated strategic urgency.

The Metalnomist Commentary

This project matters because red mud converts a liability into a domestic critical minerals option. However, investors will watch recovery yields, purity specs, and unit costs versus imported material. Therefore, the pilot results will decide whether flash joule heating becomes a scalable US pathway for gallium and scandium.

US Rare Earth Supply Gets $134mn Boost for Waste-Based Processing Projects

US Rare Earth

US rare earth supply efforts are gaining another $134mn in federal support as the Department of Energy backs two demonstration projects designed to recover and refine rare earth materials from domestic waste streams.

US rare earth supply development will focus on projects led by the Colorado School of Mines and Phoenix Tailings. Both groups have been selected for award negotiations under the DOE’s Rare Earth Element Demonstration Facility Program.

US rare earth supply remains constrained by limited domestic separation, refining and metallisation capacity. The latest awards target those midstream gaps rather than simply adding new mining projects.

The projects are also notable because both will use waste-derived feedstock. That could create new rare earth supply without depending entirely on conventional mines.

Louisiana Project Targets Rare Earths From Bauxite Waste

The Colorado School of Mines-led project will develop a demonstration facility near the Gramercy alumina refinery in Louisiana’s St John the Baptist Parish.

The facility will process critical mineral-rich bauxite waste into separated rare earth oxides and then refine those oxides into rare earth metals.

This approach is strategically important because alumina production creates large waste streams that can contain recoverable critical minerals. Extracting rare earths from existing residues could turn an environmental liability into a domestic resource.

The project also connects the aluminium and rare earth value chains. Bauxite is primarily processed for alumina, but recovering additional metals could improve resource efficiency and create new revenue streams.

Colorado School of Mines will work with ElementUSA, Pacific Northwest National Laboratory, Principal Minerals and Rare Earth Technologies.

The project therefore combines academic expertise, national laboratory capability and industrial partners. That structure could help move rare earth recovery technology from laboratory development toward commercial-scale deployment.

Phoenix Tailings Adds Domestic Rare Earth Metal Capacity

Phoenix Tailings will build a separate demonstration-scale facility focused on producing high-purity rare earth metals from waste-derived domestic feedstock.

This is especially important because rare earth metal production remains a major bottleneck in western supply chains. Separated oxides still need to be converted into metals and alloys before they can support permanent magnet manufacturing.

Phoenix Tailings will collaborate with the Massachusetts Institute of Technology on the project.

The company’s focus on waste-derived feedstock also supports a circular supply model. Industrial residues, scrap and other secondary materials can complement mine supply while reducing reliance on imported rare earth inputs.

For the US, the strategic objective is integration. Domestic mining or recycling alone is insufficient unless separation, refining, metallisation and downstream manufacturing are also available.

The DOE funding shows that federal policy is increasingly targeting these missing processing stages. If the projects scale successfully, they could strengthen domestic supply for magnets, defence systems, electronics and advanced manufacturing.

The Metalnomist Commentary

The US is increasingly treating industrial waste as a critical minerals resource. The real value of these projects lies in proving that domestic residues can be converted into separated oxides and high-purity metals at commercial scale.

Australian Firm Meteoric Resources to Supply Rare Earths for U.S. Manufacturing

Meteoric Resources, an Australian Securities Exchange-listed company, announced today that it will supply 3,000 metric tonnes of rare earth oxide from its Caldeira project in Minas Gerais, Brazil, to Ucore Rare Metals, a Canadian firm. The rare earth oxides will be used at Ucore's new plant in Louisiana, marking a significant step in North America's efforts to secure critical minerals necessary for advanced manufacturing and technology.

The supply deal, formalized through a memorandum of understanding, also includes a provision for Meteoric to supply at least 3,000 metric tonnes per year of neodymium, praseodymium, terbium, and dysprosium. These rare earth elements are essential in the production of high-performance magnets used in electric vehicles, wind turbines, and various other high-tech applications.

Ucore Rare Metals plans to commence production at the Louisiana facility by the end of 2025, with full commercial operations expected to begin in the first half of 2026. This partnership is seen as a strategic move to bolster U.S. supply chains for critical materials, reducing dependence on Chinese imports, which currently dominate the global market.

Meteoric Resources has been actively expanding its presence in the rare earth sector. In addition to the Ucore deal, the company signed supply agreements with a Brazilian rare earth magnet facility in June and with Neo Performance Materials in May. These agreements position Meteoric as a key player in the global rare earth supply chain, particularly at a time when demand for these materials is expected to surge.

The collaboration between Meteoric and Ucore underscores the growing importance of securing reliable sources of rare earth elements, as countries and companies alike seek to mitigate risks associated with supply chain disruptions and geopolitical tensions.

Fulton Asset Management acquires AFCO to deepen metals-focused building products play

AFCO Industrie

Fulton Asset Management acquires AFCO to expand its metals and building products footprint. The deal adds vertically integrated capacity in aluminum, fiberglass, and vinyl. Fulton Asset Management acquires AFCO as part of a broader portfolio in metals and manufacturing. With the acquisition, Fulton Asset Management acquires AFCO while keeping the existing leadership team in place.

What AFCO brings to Fulton’s portfolio

AFCO manufactures aluminum columns, hand railing, and millwork door components for residential markets. It also offers OEM contracting and metal fabrication services. Vertical integration supports speed, cost control, and consistent quality across extrusion, finishing, and assembly. The company’s Louisiana base complements Fulton's U.S. industrial network.

Implications for aluminum and building products supply chains

The acquisition strengthens aluminum value chain coverage from design to fabrication. Therefore, Fulton gains better access to residential renovation and light construction demand. Meanwhile, OEM and fabrication services enable cross-selling into aerospace-adjacent and industrial accounts. Financial terms were not disclosed by the companies.

The Metalnomist Commentary

This move consolidates midstream aluminum capability inside a private equity platform. Watch for capex in extrusion, coatings, and railing systems to scale regional share. Retaining AFCO’s team suggests continuity while Fulton pursues portfolio synergies.

First Solar Tariff Revisions Lift 2025 Sales Guidance and Shift Module Mix

First Solar

First Solar tariff revisions are reshaping 2025 sales plans and regional mix. The company raised guidance after negotiated duties on Asian imports. First Solar tariff revisions also sharpen cost risks and near-term pricing dynamics.

Guidance rises as duties reshape import economics

First Solar tariff revisions include 25pc on Malaysia and 20pc on Vietnam. As a result, management lifted 2025 module sales to 16.7–19.3GW. International sales now target 7.2–9.5GW, up from 6–9.5GW. US-made volumes remain 9.5–9.8GW for 2025. The firm still warns of Section 232 uncertainty on polysilicon. It also monitors a possible 25pc levy on India.

Costs, capacity ramp, and backlog support the outlook

Tariffs could cost $70mn/yr on production and $80–130mn on imports. If customers resist price pass-throughs, First Solar could idle lines. However, capacity ramps in Alabama continue, with Louisiana qualification expected in October. Second-quarter output reached 4.2GW, including 2.4GW in the US. International plants produced 1.8GW in the quarter.

Commercial traction remains solid with a 64GW bookings backlog through 2030. Meanwhile, revenue guidance increased to $4.9–5.7bn for 2025. Second-quarter revenue rose 9pc year on year to $1.1bn. Quarterly profit slipped 2pc to $342mn amid tariff and mix effects.

Policy remains the key swing factor for pricing and margins. US baseline import tariffs sit at 10pc since 5 April. First Solar tariff revisions interact with that floor to influence landed costs. Therefore, international units could flex lower if pass-throughs stall.

The Metalnomist Commentary

Tariff-driven repricing favors domestic thin-film supply in the near term. Yet margin outcomes hinge on pass-through discipline and buyer mix. Watch the India tariff risk and Section 232 actions; either could tighten module spreads again.

First Solar Module Sales Hit Record as US Manufacturing Capacity Expands

First Solar

First Solar module sales reached a record high in 2025 as the US thin-film solar manufacturer benefited from strong domestic demand and a changing tariff environment. The company shipped 17.5GW of modules, up 24pc from its previous record of 14.1GW in 2024, and slightly above its revised annual guidance.

First Solar module sales also translated into stronger revenue. Net sales rose by $1.01bn from 2024 to reach $5.2bn in 2025. Fourth-quarter sales increased to $1.7bn, reflecting continued momentum in utility-scale solar demand and the company’s strong position in the US market.

The outlook for First Solar module sales remains solid in 2026. The company expects to sell 17-18.2GW of modules this year, including 12.6-13.1GW in the US alone. However, its contracted backlog fell to 50.1GW from 68.5GW a year earlier, showing that growth remains exposed to project timing, policy uncertainty, and customer procurement decisions.

US Solar Manufacturing Becomes the Core Growth Engine

First Solar is shifting more production toward the United States as domestic manufacturing becomes a strategic advantage. The company produced 16.1GW of modules in 2025, including 10GW from US facilities, 2.8GW from India, and 3.3GW from other regions outside the US and India.

For 2026, First Solar expects total production of 16.5-17.5GW. US production is forecast to rise sharply to 13-13.3GW, while Indian output is expected at 2.6-2.8GW. Production from other regions is expected to fall to 0.9-1.4GW, showing a clear rebalancing of the company’s manufacturing footprint.

The company is also expanding its domestic capacity base. First Solar began commercial production at a new Louisiana facility this year, its fifth manufacturing site in the US. A 3.7GW plant in South Carolina is expected to begin production from the fourth quarter, further strengthening the company’s US solar supply chain position.

Tariff Uncertainty Reshapes Global Solar Production

Tariff uncertainty is becoming a major factor in solar manufacturing strategy. First Solar expects significant underutilisation at its plants in Vietnam and Malaysia because demand for output from those facilities has been constrained by trade policy uncertainty.

This shift highlights how solar supply chains are being reorganised around policy risk as much as cost. Buyers increasingly want modules that can avoid tariff exposure, qualify for domestic incentives, and support long-term project certainty. That gives First Solar an advantage because its US manufacturing base aligns with domestic energy security and industrial policy goals.

Still, the company’s 2026 sales target of $4.9bn-5.2bn suggests revenue may not grow sharply despite higher expected module volumes. This reflects the complex balance between pricing, product mix, policy incentives, and manufacturing utilisation across different regions.

The Metalnomist Commentary

First Solar’s 2025 record shows that solar manufacturing is becoming a policy-driven industrial sector, not only a renewable energy market. The company’s US capacity expansion gives it a strong position, but tariff uncertainty will continue to reshape where modules are made and sold.

First Solar Holds Guidance in 2Q

US solar module manufacturer First Solar kept its 2024 volume and revenue guidance unchanged, even as quarterly bookings were down. The company expects to sell 15.6GW-16.3GW and earn $4.4bn-$4.6bn in revenues for 2024, flat from prior guidance.

Bookings were off by 90% to 0.9GW in the second quarter from a year earlier. Year-to-date bookings declined to 3.6GW compared with 21.1GW in the same period of 2023.

Solar module production hit a quarterly record of 3.7GW, compared with 2.8GW in the same period of 2023, when the company was rolling out its Series 7 modules.

First Solar produced 2.5GW of its Series 6 modules in the quarter and 1.2GW of its Series 7 modules.

The company also announced the expansion of its Ohio plant was completed, with commercial shipments starting at the end of the second quarter. The expansion increases its manufacturing capacity in Ohio by nearly 1GW/yr to almost 7GW/yr.

First Solar still expects its 3.5GW/yr plant in Alabama to come online in the third quarter of 2024, while its 3.5GW/yr plant in Louisiana is scheduled to begin production in the second half of 2025.

These expansions are part of the company's long-term plan to grow its global production capacity to 21GW/yr by the end of 2024 and 25 GW/yr by the end of 2026 — US capacity from these expansions would be 14.1GW/yr.

The company still expects to roll out its copper replacement technology, which reduces copper doping with alternative materials and as a result the long-term degradation rate of modules, in the fourth quarter.

Total bookings narrowed to 75.9GW from 77.8GW a year earlier, still maintaining orders out through 2030, the company said.

Second-quarter profit rose to $350mn from $171mn a year earlier, as revenue grew by nearly 25% to $1bn from the same period of 2023.

Syrah Resources Secures $165 Million Tax Credit for Expansion in the U.S.

Syrah Resources

Boosting Production Capabilities

Syrah Resources, an Australian graphite producer, has been awarded a substantial $165 million tax credit under the U.S. Inflation Reduction Act. This financial boost is earmarked for potential expansion of its Vidalia Active Anode Material (AAM) plant located in Louisiana.

Expansion Plans and Raw Material Sourcing

The tax credit will facilitate the expansion of the Vidalia facility’s production capacity from 11,250 metric tonnes per year to 45,000 metric tonnes per year. This significant increase will support the growing demand for anode materials necessary for battery technologies. Additionally, the Vidalia facility processes natural graphite from Syrah's Balama operation in Mozambique, which is integral to the production of high-quality anode materials.

First Solar Lowers 2024 Guidance Amid Declining Bookings and Production Challenges

US Solar

First Solar, a leading US-based solar module manufacturer, has revised its 2024 guidance downward, reflecting a significant 13% decrease in expected sales volume. The company now anticipates producing between 14.2GW and 14.6GW, a decrease from the previously projected 15.6GW to 16.3GW. This adjustment is largely attributed to waning quarterly bookings and challenges related to manufacturing issues.

Despite the lowered forecast, First Solar’s third-quarter results showed a 17% increase in profits year-over-year, reaching $313 million. The company’s solar module production also reached new heights, with a record-breaking 3.8GW produced during the quarter. However, bookings were down by a stark 88%, with only 0.9GW booked, marking a significant dip due to the company’s selective contracting approach.

Key Factors Behind the Revised Guidance

The primary reason behind the lower guidance is a decline in bookings, which dropped by nearly 90% compared to the same period last year. Mark Widmar, First Solar’s CEO, attributed this slowdown to the company’s highly selective contracting strategy, which limits its order volume but aims to secure more stable, long-term contracts.

Moreover, manufacturing issues have prompted First Solar to set aside funds for a product warranty reserve charge, further impacting the company’s financial outlook for 2024. However, production remains strong, with the Series 6 module manufacturing at 2.6GW—a 4% increase over the previous year—and the Series 7 module seeing over double the production year-over-year at 1.5GW.

Ongoing Expansion and Technological Innovation

Despite the challenges, First Solar continues to push forward with its expansion plans. The company recently began commercial operations at its new 3.5GW/year facility in Alabama, and its Louisiana expansion is on track to begin production in late 2025. These expansions will elevate First Solar’s US production capacity to 14GW/year, with a total global capacity of 25GW/year.

Additionally, the company has made strides in solar technology with the development of CuRe technology, which aims to reduce reliance on copper by using alternative materials for doping. Production of the CuRe product will begin in the fourth quarter of this year, with plans to produce up to 0.4GW through the first quarter of 2025.

Financial Snapshot and Future Outlook

In terms of revenue, First Solar’s third-quarter sales fell by 12% compared to the previous quarter, reaching $888 million, though they saw a 10% increase compared to the same quarter last year. The company has a substantial backlog of 73.3GW, expected to sustain production through 2030, giving it a long-term growth outlook despite current challenges.

While the short-term outlook has been tempered by lower-than-expected bookings, First Solar’s strong production capabilities, strategic expansion, and cutting-edge technology position it well for future growth in the global solar market.