Hey Slymeat - I wrote this about a year back (I don't think I copy pasted any of it, but it's been a while) when I was trying to research ASM/the rare earths industry. It's a pretty opaque industry and I found accurate information on some things very hard to get unless you were willing to pay $1000s of dollars. There was a reasonable amount of information conflicting between sources. Obviously DYOR - this was my notes and I have certainly missed things.
Overview of the Rare Earths Industry
General Overview
The Rare Earth Industry is small and only about $4 billion dollars (I don’t know how this is calculated), though most predictions have the industry growing at 10% per year. I suspect it might grow more quickly than this, particularly if the price kicks up. NdPr accounts for 91% of the total value of TREO. (https://rainbowrareearths.com/our-projects/rare-earth-elements/)
Many of you would have heard that rare earth metals aren’t all that rare. They aren’t rare on absolute terms, but they are very rare in economically mineable grades and ore bodies. Effectively, our ability to access them is very rare and this is unlikely to change.
In addition to their rarity, they are also very difficult to process. Rare Earth’s are often found together and usually require a very difficult technical processing involving both separation and metalisation.
Why are rare earth metals important? Strategically, it’s mainly magnets. Neodymium is used in many products that require electricity and motors, including cars and turbines. Essentially, Neodymium (Nd) magnets (with Pr, Fe, and B) are the strongest permanent magnet known to man and there simply aren’t replacements. The Neodymium magnets usually have other rare metals mixed with it, depending on whether you need performance at temp, high coercivity, or wish to reduce the price. These metals are often very difficult to substitute, which is why they are important. Rare Earths are also used in small quantities for a large range of computer goods, etc, which is very important commercially, and there are some important military applications, particularly in alloys.
I think that the military threat of this is sometimes overstated (we just don’t need that much for military purposes), but the commercial dependence is probably understated. China has deliberately dominated this industry, using its market power to attack competitors. They were successful in dominating the industry prior to 2010, cut supplies of rare earths to Japan in 2010 over a South China Sea dispute, destroyed Mountain Peak after this, and may even have been involved in the political issues Lynas has had in Malaysia. (I think Terbium is important for military)
The market is opaque and finding prices for most of these metals was hard, with limited data available on previous prices. Prices were often in oxides or in Yuan.
Summary of Rare Earths - https://lynasrareearths.com/summary-of-rare-earths/
Ore deposits and reserves
China has by far the vast majority of the world’s ore reserves (~37%), with significant other deposits in Vietnam (effectively China controlled) (18%), Russia (10%), and Brazil (18%). (USGS) Perhaps 80% of China’s reserves (~30% of world reserves) come from the Bayan Obo mine.
Ore Mining
China also dominates the mining space. Estimates are that China produces around 51% of the ore officially, another 19% through illegal mining (Yes, 19% of world production…), US 10%, Australia 8%, and the rest of the world 15%.
The reason more is not produced outside of China is that many of the deposits outside of China are not economical and China is not afraid to use its market power.
Separation and Refining
The problem a lot of miners have is that separating the different products out is extremely complicated. They can sell their product as a concentrate, but this means that they suffer an extremely steep discount.
Currently this part of the process is dominated by China.
The only companies currently separating rare earths outside of China on a commercial scale that I’m aware of are Lynas (Australia), MP Materials (USA), and Neo Performance Metals (Europe). There are, however, a number of companies developing this ability, including ASM (Demonstration pilot plant completed in 2008), and some have demonstrated it in a pilot plant. I’m not too worried that ASM will be able to separate their rare earths - they have been working on their project for a long time and from what I’ve seen are much more developed than most other projects.
Metalization
China completely dominates this area.
I believe that ASM is the only company currently able to do this on a commercial scale (pilot plant is going into commercial production) for most rare earths, though Neometals seems to be able to do it for some strategic metals. There is apparently the capacity to do this in Japan somewhere and I suppose the USA must be able to do it in some capacity also (their military would not be that mad).
Since I wrote this there seems to be more action on this area - Lynas seems to be working with MP materials.
Magnets
China also dominates this space, though Japan and the USA can produce some, and South Korea where ASM operates is looking to be able to produce these. I believe MP Materials and other companies may be looking to develop this.
Zirconium, Niobium, and Hafnium
In addition to rare earths, Zirconium, Niobium, and Hafnium are also significant commodities for ASM.
Niobium is mainly used to improve the qualities of steel. It commands a high price that is normally stable, but this may drop off with the slowing down of Chinese construction.
Zirconium is used for a range of things in its metal and other forms.
Hafnium is a very minor metal and usually produced as a byproduct of producing zirconium for use in nuclear facilities. ~70t are produced annually globally, and ASM’s facility will have the capability to well over double worldwide Hafnium production. It remains to be seen whether increased supply can create a stronger market for Hafnium through regular supply, or whether this will mean ASM can sell only a fairly limited amount of the metal.
Ballparks on market size for metals
The market size here is a pain to work out. A 3-4 billion dollar figure is thrown around but I don’t know whether this figure includes magnets or not - that really matters! Apparently 91% of that is Nd and Pr. (not confirmed, please research)
...
For competition, Mp materials appear to want to be serious competitor in this area in a few years, Lynas may move into it, Neo Metals are worth watching, and Japan apparently has some capacity, but I haven't been able to find anything. Pensana wants to produce metals, but I think they are ~5 years behind.
With those disclaimers… Total annual metal value by metal may be…
Rare Earths - ~2-4 billion?? (Let’s say 3 bill, depending on whether industry includes magnets and how much value in that) (Nd & Pr 91%)?
Zirconium - ~2 billion?
Titanium Metal (not pigment) - 4 billion???
Niobium - 7 billion??? (Mostly FerroNiobium)
Hafnium - 52 million (I think ASM hopes this will expand) - Most of this comes as a byproduct of I think zirconium in nuclear uses.
Assuming ASM captured maybe 20% of 3 bil Rare Earths metalization, 10% of Zirconium, 20% of Titanium, 2% of Niobium (mostly turned into ferro-niobium), and 50% of Hafnium, that would mean a potential revenue of ~1765 mil, with a profit of maybe ~150-300 mil per year.
Greater than 10-20% market capture may be reasonable given that Lynas and maybe only 1 or two other competitors may come into the market. Given China’s dominance, I think it would be unrealistic to expect a figure greater than 50%. It really does depend on whether that 4 billion industry figure includes magnets though...
These ballpark figures seem to suggest that it’s feasible for at least 2-3 plants to be built, possibly more.
Main Competitors
China (will use market power to bankrupt companies)
55% of global mine output (https://roskill.com/market-report/rare-earths/)
Maybe 90% of separation and metallization.
Lynas (currently produces separated oxides etc. - developing processing in the USA) Has signed agreements with companies in the US to develop separation facilities for both light rare earth and heavy rare earth. I am not sure whether this touches on metallization.
Neo Performance Materials Inc. (part of old Molycorp) (NEO.TO)
Apparently owns the “only commercial rare earth separation facility in Europe.” I don’t think these guys can metalise most rare earths yet.
MP materials (US - Mountain Pass)
Produces maybe 15% of rare earth’s consumed, they are developing the ability to separate NdPr oxide, Lanthanum, and Cerium. They have announced that they are seeking to build a metal, alloy, and magnet making manufacturing facility in the US, but I am not sure how they are doing this.
Other Potentially significant groups include:
Reetec - Has developed a separation technique in EU - seems to be close to commercialising. Separation by itself is not a major threat.
Vital Metals - looking to sell rare earth oxide to reetec
Pensana - Has a project in Angola - Wants to set up a mine to magnet supply chain, but seems maybe 3-5 years behind ASM.
Arafura - REO
Energy Fuels
Appia Energy
Search Minerals
Rare X
Useful Documents and Reading
Breakdown of the Sector - https://7b5ada19-e8f1-46c1-9324-1cd5cb6510ef.filesusr.com/ugd/53af0a_0c4e31fb12b948acb1d36879922109ea.pdf
Scoping Study - https://asmd.irmau.com/site/PDF/0d270d08-afbc-436d-adac-8075042290ce/SCOPINGSTUDYDEMONSTRATESFEASIBILITYOFMETALSPLANT
Statistics on REE - https://www.usgs.gov/centers/nmic/rare-earths-statistics-and-information
Great general overview of the rare earth industry
https://www.youtube.com/watch?v=GSgI58fLT7s
Australian Gov. Rare Earth Information
https://www.ga.gov.au/data-pubs/data-and-publications-search/publications/australian-minerals-resource-assessment/rare-earths