Ucore preps Louisiana plant for 2026 REE output

Executive Summary

• Ucore Rare Metals Inc. provided a significant operational update on its RapidSX rare-earth element (REE) separation technology commercialization and its $22.4-million U.S. Department of War (DoW) Other Transaction Agreement (OTA).
• The company has successfully completed approximately 5,700 hours of REE processing at its Kingston, Ontario, Commercialization and Demonstration Facility (CDF), demonstrating the ability to produce various REE groups and products using a single RapidSX machine.
• Full commercial-scale construction of the Louisiana Strategic Metals Complex (SMC) is underway, with the installation of RapidSX Machine No. 1 planned for mid-2026 to commence heavy rare-earth processing in the United States.

Key Details

• Project Funding: The update relates to a $22.4-million (U.S.) Other Transaction Agreement (OTA) with the U.S. Army Contracting Command-Orlando (ACC-ORL).
• CDF Demonstration Progress:
  • Since December 2023, Ucore has operated and improved its 52-stage RapidSX demonstration plant.
  • Completed approximately 5,700 hours of REE processing with tonnes of heavy mixed rare-earth oxides (MREO) in an automated, simulated 24-hour-per-day commercial production environment.
  • Produced LaCe, NdPr, SmEuGd, Sm, Gd, HoYErTmYbLu, TbDy, Tb, and Dy rare-earth element groups and products.
  • Demonstrated the use of one RapidSX machine for all splits and multiple feedstocks.
  • Established protocols for precise and robust manipulation of standard solvent extraction chemistry.
• Laboratory and Quality Control:
  • Constructed a dedicated production environment ICPMS laboratory with seven days per week support.
  • Analyzed over 25,000 samples, proving that RapidSX and conventional solvent extractant (CSX) yield virtually identical chemistry results.
  • Developed laboratory and sampling protocols for the Louisiana SMC operations.
• Technical Advancements (RapidSX vs. CSX):
  • Throughput: Two to four times faster throughput compared to conventional methods.
  • Cost & Footprint: Constructed primarily from commercial-off-the-shelf (COTS) equipment with a significantly reduced individual stage footprint, leading to a smaller physical plant, reduced environmental impact, and overall capital expenditure (capex) reduction.
  • Operational Flexibility: Ability to quickly reconfigure operational equipment (extract, scrub, strip, etc.) for specific separation requirements within hours; ability to stop and immediately restart for planned or unplanned events.
• Louisiana SMC Construction Status:
  • Full commercial-scale work is underway for the installation of RapidSX Machine No. 1 in mid-2026.
  • Activities include field and design engineering, supporting infrastructure equipment, permitting activities, and long-lead material and equipment procurement.
  • Conducting CDF scale-up trials for full-scale RapidSX machine components.
  • Procuring heavy feedstock for initial testing, commissioning, and trials, including coordination trials starting at the CDF and culminating at the Louisiana SMC.
• Strategic Context:
  • The Louisiana SMC is a developing REE separation and oxide production facility focused on mid (SmEuGd) and heavy (initially Tb and Dy, potentially followed by Y) rare-earth elements, with the ability to also produce NdPr REO.
  • The goal is to disrupt the People's Republic of China's control of the North American REE supply chain.

Notable Quotes

• "The nearly two years of CDF demonstration work undertaken by Ucore has been done with deliberate coordination with the Louisiana SMC production rollout pathway. The result is a technically proven and derisked commercialization pathway to commence heavy rare-earth processing in Louisiana in 2026," stated Mike Schrider, PE, vice-president and chief operating officer of Ucore.
• "With our planned sequential deployment of RapidSX machines, based on the unique demonstrated ability to produce products with only one RapidSX machine. Ucore has established a blueprint for smart deployment of capital, with minimal commercial risk, while getting to early heavy rare-earth production within the United States of America -- a stated objective of the initial OTA."