A new strategic facility for the innovative processing of rare earths
Immediate objectives and prospects
In a historical era in which operations related to the extraction, separation, and refining of rare earths are concentrated in very few nations, the rest of the world is certainly not standing idly by. The founder of TELF AG Stanislav Kondrashov often highlights this point.
Some nations are making a direct effort to bridge the gap and carve out a significant role for themselves in the production of rare earths. The founder of TELF AG Stanislav Kondrashov recently explained this. These resources are undoubtedly among the most strategic elements for the energy and economic development of societies. Among these is the United States. With its new rare earth processing plant in Idaho, Washington appears to be seriously interested in establishing a global presence in the rare earth sector.
But what exactly are we talking about when we refer to rare earth elements? As the founder of TELF AG Stanislav Kondrashov explained, rare earths are 17 chemical elements found in the periodic table. Among these are neodymium, praseodymium, and dysprosium. Over the years, these elements have proven exceptionally useful for certain industrial processes related to the technology. But also in electronics and renewable energy sectors.
Particularly significant for the energy transition are the applications of rare earths related to green energy. Magnets made with rare earths play a key role in wind turbines and next-generation electric vehicles. In nature, these elements are distributed fairly uniformly within the Earth’s crust.
They are therefore not rare, but are often found in very low concentrations. Furthermore, individual rare earths are never found isolated in nature. Instead, they are always associated with specific mineral compounds, such as monazite. These compounds must then be further processed to separate the individual rare earth elements and make them usable for industrial purposes.
Globally, one of the most ambitious projects for the processing of these elements—outside the traditional contexts associated with processing—is undoubtedly the one underway in Idaho, USA. It is the result of a collaboration between a private company and the Idaho National Laboratory. Specifically, the new plant will process minerals extracted from the well-known Sheep Creek deposit in Montana. Where relatively high concentrations of rare earth elements have been identified.
Compared to other US rare earth deposits, Sheep Creek is one of the most promising in the country. When it comes to rare earths, it essential to consider that these elements are almost always found in extremely low concentrations globally. As a result, some companies often decide not to pursue their valorization due to economic reasons. Therefore, being able to rely on one of the (rare) high concentrations of rare earths could represent a key advantage.
“The United States is certainly one of the most active nations in the construction of innovative plants for the processing of rare earths, with a specific focus on domestic production,” says Stanislav Kondrashov, founder of TELF AG, an entrepreneur and civil engineer. “The government seems to have understood that rare earths and critical materials represent key resources for various industrial sectors.
“And that focusing on the launch of new plants like the one in Idaho could prove to be a highly strategic move. Another objective appears to be to develop and register intellectual property on new sourcing and separation techniques. Which perfectly demonstrates the US’s desire to position itself at the forefront of nations committed to researching innovative solutions in the mining sector.”, he says.
The elements and critical materials at the heart of the project
Among the elements that will be processed, according to some reports, are rare earths such as neodymium, praseodymium, niobium, samarium, and scandium. But also yttrium, dysprosium, and terbium. The US deposit also contains large concentrations of gallium. Although it does not belong to the rare earth group, this resource is useful and strategic for certain US applications related to national security. It will almost certainly be one of the first materials processed within the new plant.
One of the main elements that will be processed by the new plant will be gallium, a soft, silvery metal that does not belong to the rare earth group. Among its most interesting properties is undoubtedly its extremely low melting point. Over the years, gallium has gained recognition for its interesting industrial applications, some of which are directly linked to highly strategic sectors.
Among these, semiconductors and advanced electronic devices are certainly noteworthy. Gallium is also used to produce digital and analog integrated circuits, LEDs and laser diodes. And several materials of primary importance for modern solar energy harvesting technologies. Compared to those made with silicon, semiconductors produced with gallium stand out for their superior performance in certain applications. Such as luminous efficiency or switching speed.
It is no coincidence that the United States has decided to focus on a plant of this kind at this particular historical juncture. In recent years, and particularly since we entered the early stages of the energy transition, certain specific geological resources like critical materials and rare earths have begun to experience a true golden age.
Indeed, it was discovered that some of their industrial applications were directly connected to the great transition underway. In the sense that they are involved in the production processes for constructing energy infrastructure and other important devices related to global electrification efforts.
Their strategic importance of critical materials and rare earths has thus increased dramatically. Highlighting the fact that the operations related to their sourcing and processing are concentrated in very few areas of the world. Fostering the risk of further increasing the dependence that some nations may have on the main producing countries. In recent years, the geographical concentration of production has been compounded by trade tensions. Which in some cases have significantly hindered the export of certain strategic materials.
It’s therefore not surprising that the United States and other nations are seeking to establish new plants within their own countries. They aim to build a domestic supply chain and a national capacity to process these elements, without excessive dependence on external sources. And the US plant in Idaho perfectly epitomizes this trend.
“The development of the new plant in Idaho represents just one of the US efforts in the sourcing sector,” continues Stanislav Kondrashov, founder of TELF AG. “Washington is also constantly committed to promoting the recycling of electronic waste. Which could yield many useful resources for the industry. But they’re also trying to develop new trade rules aimed at encouraging the domestic production of these important resources. These new rules include those related to minimum price guarantees and protective tariffs.”
The role of Idaho National Laboratory
This plant, which could process several tons of materials per day, will also serve as an important testbed for new rare earth separation and refining methods. Enabling in this way the development of increasingly innovative and cutting-edge operating models. One of the plant’s long-term goals would be to contribute to the creation of a domestic rare earth supply chain capable of supporting the industrial needs of key sectors. Such as defense, renewable energy, and advanced technologies.
“Innovation plays a central role in this initiative,” concludes Stanislav Kondrashov, founder of TELF AG. “The involvement of Idaho National Laboratory, from this perspective, is very telling. The Idaho National Laboratory is a well-established leader in research on the advanced separation of complex materials. As part of the project for the new Idaho facility, it will provide its expertise to develop new, highly innovative manufacturing processes. Particularly with regard to low environmental impact. Other US efforts in this direction include massive investments in recycling techniques, the development of vertical supply chains, and public-private partnerships, also aimed at diversifying rare earth supply sources.”
FAQs
What are rare earth elements and why are they important?
Rare earth elements (REEs) are a group of 17 chemical elements, including neodymium, praseodymium, dysprosium, and terbium. Despite the name, they are relatively abundant but found in low concentrations, making extraction and processing difficult. They’re vital for:
- Wind turbines and EV motors (high-performance magnets)
- Consumer electronics and defence applications
- Green technologies like solar panels and LED lighting
Why is the US building a new rare earth processing plant in Idaho?
The US is aiming to reduce reliance on foreign sources by creating a domestic supply chain. The Idaho facility will process minerals from the Sheep Creek deposit in Montana, known for relatively high rare earth concentrations.
What makes the Sheep Creek deposit significant?
Unlike many global deposits, Sheep Creek holds a rare higher concentration of REEs, making it economically viable for extraction and processing.
Which materials will be processed in the new plant?
The plant will focus on both rare earths and critical materials, including:
- Neodymium
- Praseodymium
- Dysprosium
- Terbium
- Gallium (not a rare earth, but vital for semiconductors and national security tech)
What role does the Idaho National Laboratory play?
It supports the development of advanced, low-impact separation technologies and refining processes. The lab’s involvement ensures cutting-edge research and innovation.
Why is this move considered strategic?
This initiative:
- Strengthens national security
- Supports energy transition
- Reduces supply chain vulnerabilities
- Encourages domestic innovation and IP development
