Aclara Inaugurates Rare Earth Separation Pilot Plant in Virginia Tech to Advance U.S. Supply of Heavy Rare Earths

Executive Summary

• Aclara Resources inaugurated a rare‑earth separation pilot plant at Virginia Tech, marking a key step toward its U.S. industrial strategy.
• The pilot will validate the company’s proprietary separation technology using feedstock from ionic‑clay deposits in Brazil and Chile and generate data for an AI‑driven digital twin.
• Aclara disclosed plans for a commercial‑scale separation facility in Louisiana, with an estimated $277 million capital investment and a target start‑up by mid‑2028.

Key Details

• Pilot Plant Commissioning
• Location: Virginia Tech, Blacksburg, VA.
• Designed to produce separated Dy, Tb, NdPr from high‑purity mixed rare‑earth carbonates.
• Fully staffed and ready for continuous 24/7 operation beginning April 2026.

• First light‑rare‑earth oxides (NdPr) expected May 2026; first heavy‑rare‑earth oxides (Dy, Tb) expected August 2026.

• Technology Validation

• Uses Aclara’s proprietary rare‑earth separation process with feedstock from ionic‑clay deposits in Brazil and Chile.
• Operational data will support engineering, ramp‑up, and optimization of the future commercial plant.

• Collaboration with Argonne National Laboratory to develop an AI‑driven digital twin of the separation process.

• Strategic Partnerships & Attendance

• Attended by senior leaders from Virginia Tech, Argonne NL, L3 Process Development, U.S. DOE, and the U.S. International Development Finance Corporation (DFC).

• Comments from Aclara Chairman Eduardo Hochschild, DOE Deputy Assistant Secretary Christopher Saldaña, DFC Managing Director David Hester, and others highlighted strategic importance for domestic critical‑minerals supply chains.

• Louisiana Commercial Facility

• Site selected: Port of Vinton, Louisiana.
• Engineering partner: Hatch Ltd.
• Estimated capital cost: ~US$277 million.
• State incentives: $46.4 million in tax credits and grants from the State of Louisiana.

• Targeted operational start: Mid‑2028, subject to financing and project milestones.

• Financial Support

• Prior DFC project‑development financing: $5 million secured for feasibility study of Brazil rare‑earth project.

• Workforce & Training

• Dedicated team of Virginia Tech PhD researchers engaged in process optimization and advanced technical analysis.
• Pilot plant serves as a training platform for workforce development in rare‑earth separation and hydrometallurgical processes.

Notable Quotes

“Demonstrating that Aclara possesses the technology to separate rare earths—including Chinese‑restricted heavy rare earths—in the United States represents a major milestone.” – Eduardo Hochschild, Chairman, Aclara

“Developing domestic capabilities for critical minerals processing strengthens U.S. energy security and manufacturing competitiveness.” – Christopher Saldaña, Deputy Assistant Secretary, Office of Critical Minerals, DOE

“DFC is pleased that our project development financing is providing vital capital to accelerate the development of Aclara's supply chain in South America.” – David Hester, DFC Managing Director for Project Development