A single ingot of neodymium praseodymium has enough power to fuel five electric vehicles. (Saskatchewan Research Council.)
A groundbreaking step in North America’s rare earth metals market is being taken by an organization in Saskatchewan, which has successfully extracted neodymium praseodymium (NdPr) from a mineral called monazite. This achievement marks a significant milestone, as the Saskatchewan Research Council (SRC) becomes the first entity in the continent to commercially produce these essential metals. Rare earth metals are critical to modern technology, with uses ranging from electric vehicles (EVs) to mobile phones, and their global supply is currently dominated by China.
The SRC’s rare earth processing facility is expected to be fully operational by next year, with the ambition to challenge China's 90% control over the rare earth market. Jeremy Harrison, Saskatchewan’s minister responsible for the SRC Treasury Board crown corporation, emphasized the difficulty of this process, stating, “The reason this isn’t happening all over the place is because it is really hard to do.”
The rare earth metals, particularly NdPr, are vital for manufacturing the strongest type of magnets used in electric vehicles. As the world continues to push for a greener future, these metals are becoming increasingly important, and there is rising global interest in developing alternative sources outside China. Muhammad Imran, vice president of rare earth elements at SRC, said that interest in developing this sector outside China has surged over the past two years.
China’s dominance in the rare earth market goes beyond supply; it also leverages its position to influence foreign policy. In December 2023, China placed a ban on exporting its rare earth processing technologies, further solidifying its stronghold. Heather Exner-Pirot, an expert in energy, natural resources, and the environment, remarked on China’s mastery of rare earth processing, partly due to its lax environmental and labour regulations. She noted, "They are experts on it. They're leaders on it, and they don't want anyone else to be able to diversify."
During one step of the process, the molten metal is poured into moulds to form ingots.(Saskatchewan Research Council.)
Processing rare earth metals can be a hazardous job, often involving extreme heat and smelting, which is why the SRC has implemented artificial intelligence to assist with some of the more challenging labour. SRC president Mike Crabtree explained that their goal was to minimize risks by enhancing existing processes with AI, stating, “We wanted to de-risk this. We did not want to create radically new processes which would introduce risk. We wanted to use existing processes, but operate them a lot smarter.”
Since integrating AI technology, the SRC has been able to process 10 tonnes of NdPr per month. By the end of 2025, they aim to scale up and produce 400 tonnes annually. This supply would be enough to help manufacture half a million electric vehicles.
Earlier in the year, SRC and Ottawa acquired a stockpile of rare earths from a mine near Yellowknife. Initially, this stockpile was intended for sale to a Chinese company, but now it will contribute to Canada’s domestic supply chain. Crabtree highlighted the importance of keeping this value in North America, saying, “What we want is that value to stay here in Canada rather than being exported. So we want to play a key role in initiating that supply chain predominantly for North America.”
Exner-Pirot expressed optimism that any diversification in the market would reduce China’s dominance, even if just by a small margin. "Any time you can reduce China's leverage in the market, it is going to be overall net positive," she stated.
Beyond electric vehicles, Canada’s rare earth capabilities also have national defence implications. The SRC plans to eventually process samarium, another rare earth metal used in defence technologies like F-35 fighter jets. Crabtree estimated the facility could process enough samarium to meet 25% of North America’s defence needs.
