DLA26BZ02-NV002 — Novel and Highly Efficient Separation Methods for Critical Rare Earth Elements

Award Maximum: $100,000 Period of Performance: 12 months Phase Type: Phase I

OBJECTIVE: The Defense Logistics Agency (DLA) seeks to provide responsive, best value supplies of related materials consistently to our Department of War (DoW) customers and other DoW stakeholders. DLA continually investigates a variety of critical minerals for more efficient means of their production, opportunities for recycling, and more competitive domestic supply chains which would lead to higher levels of innovation in current and future systems combined with benefits to other commercial and government technology applications. To reduce costly foreign reliance and/or single points of failure, DLA is looking for novel and highly efficient domestic capabilities to separate rare earth elements from mixed feedstocks. The end goal of the project would be for the development of domestic suppliers that separate industrial quantities of high purity rare earth oxides, salts, or metals, including Sc, Y, Nd/Pr, Sm, Gd, Tb, Dy, and others. New and novel ideas that would allow for competitive pricing relative to imported raw materials will have preference. Ideally, the production process would be modular and scalable. Advanced technology demonstrations for increasing production capacity, affordability and supply chain resiliency for coating techniques and processing are of high interest to DoW. These areas of materials and manufacturing technology provide potential opportunities toward achieving breakthrough advances for national defense. Proposed efforts funded under this topic may encompass diverse feedstocks and processing at any level that will result in increasing production capacity, affordability, and supply chain resiliency. Research and Development (R&D) efforts selected under this topic shall demonstrate and involve a degree of risk where the technical feasibility of the proposed work has not been fully established. Further, proposed efforts must be judged to be at a Technology and/or Manufacturing Readiness Level (TRL/MRL) 6 or less, but greater than TRL/MRL 3 to receive funding consideration. TRL 3. (Analytical and Experimental Critical Function and/or Characteristic Proof of Concept) TRL 6. (System/Subsystem Model or Prototype Demonstration in a Relevant Environment)

DESCRIPTION: Rare earth separation processes have historically been performed overseas due to challenges associated with 1) operations cost/profitability, 2) feedstock sourcing, and 3) hazardous chemistries. These issues have been further compounded by artificial price controls that prevent domestic startups from gaining a foothold in global markets. A wide range of defense platforms rely on small quantities of a variety of rare earth elements, rendering the defense industrial base susceptible to global supply chain disruptions for these critical elements. To this end, DLA seeks to develop novel and highly efficient rare earth separation technologies that are cost-competitive in the global market. New approaches that increase the domestic availability and supply chain resiliency of rare earth oxides will have preference. The ideal production process will be both modular and easily scalable.

PHASE I: Not to exceed a duration of 12 months and cost of $100,000.

Phase I will deliver a proof-of-concept demonstration of a high efficiency rare earth separation method. A technology development and commercialization roadmap will be produced along with a preliminary technoeconomic analysis. An alignment or collaboration with a relevant DoW Component organization/supplier (e.g., DoW lab, defense system program office or prime contractor) and one or more relevant DoW weapon system supply chain participants or other suitable organization is highly desirable.

PHASE II: Not to exceed a duration of 18 months and cost of $1,000,000.

Phase II will consist of establishing a pilot scale process to separate rare earth elements. Produced materials will be characterized for elemental purity and other relevant properties. Input materials will be required to be sourced domestically. A business case will be generated using both DoW and commercial markets. Collaboration with a relevant DoW Component organization/supplier (e.g., DoW lab and/or prime contractor) and one or more relevant DoW weapon system supply chain participants or other suitable organization is highly desirable. Performers will identify commercial benefit or application opportunities of the innovative processes should be developed with the intent to readily transition to production in support of DoW and its supply chains.

PHASE III DUAL USE APPLICATIONS: At this point, no specific funding is associated with Phase III. Relationships developed and progress made in Phase I and Phase II projects should result in the ability to produce to DoW orders and organic growth of business from there.