There are four steps:
- Mining.
- Beneficiation - raw dirt goes in, most of the uninteresting dirt is removed, low grade ore comes out. Mostly a mechanical process. Done at the mining site. Biggest problem is getting rid of the waste. Mountain Pass pipes it to Nevada. Really.
- Separation - low-grade ore goes in, and the various elements are separated out. Usually separate from the mine site. Currently China has over 80% of the capacity for this step. US capability in this area is weak. MP Minerals has a pilot plant. So does a startup, Ucore.[1] They claim to be scaling up. Total investment in Ucore seems to be about $55 million, which is small for the importance of this business.
- Smelting and magnet making - MP Minerals has a modest plant in an industrial park in Texas.
The US military demand for rare earths probably isn't that high compared to consumer demand.
Nobody wants to overspend, because the last two times rare earth producers overspent, the price crashed and many players went bust. The problem with this industry is price volatility vs large fixed capital expenditures. Now pricing, subsidies, and export controls are so political that volatility is worse.
[1] https://www.metaltechnews.com/story/2024/09/18/mining-tech/t...