OPERATIONS REVIEW CONTINUED
STRATEGIC REPORT
19
Rainbow Rare Earths Limited
Annual Report & Financial Statements 2023
A key workstream that forms part of the
project’s DFS is the operation of a pilot plant
in order to optimise the flowsheet and
demonstrate the efficacy of the separation
technology developed by and with K-Tech.
Phase one of the pilot plant comprises
a front end situated at the facilities of Mintek
in Johannesburg, South Africa. The front-end
process incorporates the front-end gypsum
washing, acid leach, fluoride removal via CIX,
rare earth precipitation and a sulphuric acid
agitated bake to produce a high-value mixed
rare earth sulphate. This was successfully
achieved in Q3 CY 2023, with the product
being in line with management expectations
in terms of purity, grade, reagent consumption
and overall recoveries of ca. 65%.
Phase two of the pilot plant comprises
a back end situated at the facilities of K-Tech
in Lakeland, Florida, USA. The back-end
process will water leach the mixed rare earth
sulphate into a pregnant leach solution,
perform a cerium rejection step to minimise
flows downstream (thereby further reducing
operating costs and capital expenditure) into
the CIX circuit for loading onto the cation resin
before stripping and going into the final CIC
step, which will produce the separated rare
earth oxides using K-Tech’s patented
CIX/CIC technology.
Rainbow is currently exploring the option
of permanently establishing its back-end rare
earth oxide separation process in the USA and
has identified a potential site for a commercial
scale plant.
Mineral Resource Estimate (“MRE”)
During the Year, the Group published an
updated JORC compliant MRE for the project,
which upgraded a portion of the Inferred
Resource to Measured and Indicated and
confirmed a total Resource of 30.4 Mt at 0.44%
TREO, with the high-value, permanent magnet
elements Nd and Pr representing 29% of the
TREO in the rare earths basket, as well as
economic quantities of Dy and Tb. The full MRE
can be accessed at
https://www.rainbowrareearths.com/
project/phalaborwa/.
The technical team is currently focused on
evaluation and confirmation of the bulk density
at depth of the gypsum stacks, also with input
from Ardaman. It is probable, based on
Ardaman’s experience and techniques used
to evaluate the resource of similar
phosphogypsum stacks, that the in-situ dry
density for the stacks below the water table
is higher than that for the upper dry material.
This may result in an increase in the MRE.
Sustainability-related opportunities
Rainbow’s operations at Phalaborwa will serve
to clean up a legacy environmental issue –
namely the build-up of acid water associated
with the historic gypsum stacks, which are
currently unlined.
Rainbow’s front-end plant process will
neutralise the acid water and the plant’s
by-product will be a cleaner “benign” gypsum
which no longer contains any acid water
residue. The neutralised water will be used
in the closed-circuit plant process, thereby
eliminating the need to draw on an external
water source.
The benign gypsum will be deposited
on new stacks which are lined according to
International Finance Corporation standards
and Equator Principles. Post Year-end,
Rainbow signed a letter of intent to enter
into an offtake agreement with NEXUS,
under which NEXUS will acquire the benign
gypsum and on-sell it to both South Africa
and neighbouring countries.
This agreement will see the stacks at
Phalaborwa eventually fully depleted, allowing
for a complete environmental rehabilitation of
the site, as well as having a positive socio-
economic effect on local industry.
An important part of an independent
and ethical rare earths supply chain
Phalaborwa is a unique project in that it offers
a near-term source of responsible production
of the critical rare earths NdPr, Dy and Tb,
all of which can be delivered as separated
oxides, unlike most projects which produce
a mixed rare earth product.
These credentials are demonstrated by the
backing for Rainbow and Phalaborwa by
TechMet, the critical minerals champion which
is itself partially funded by the US DFC, and the
strategic supply agreement with UK-based
LCM, which is looking to negotiate a binding
offtake agreement for Phalaborwa’s
separated rare earth oxides.
THE IMPORTANCE OF HEAVY RARE
EARTH ELEMENTS (“HREES”)
Heavy rare earth metals are defined by
their higher atomic weights relative to light
rare earths. They are less common, and
some elements within the group are facing
shortages as demand outpaces supply.
The incorporation of Dy and Tb into REPMs
delivers enhanced operating performance
by enabling them to operate at higher
temperatures (magnets with HREE can
operate up to 240°C as compared to 60°C
for those magnets without HREE), without
losing their magnetic properties (high
coercivity). This makes them essential to
the REPMs used in EVs, wind turbines and
military applications.
Of all the critical minerals, McKinsey
assesses that Dy and Tb are amongst
the highest risk for supply shortages
and it was telling that China actually
decreased its production quota for
HREEs in H1 2023, which is considered
likely due to resource scarcity.
While there are some processing projects
in the development pipeline, there are
currently no facilities producing separated
HREE oxides outside of Asia.
Relevance to Rainbow: The Phalaborwa
project will produce all four of the critical
REPM REEs, including Dy and Tb. If the
Group decides to establish the plant back-
end process permanently in the USA, this
could establish Rainbow as one of the first
producers of separated rare earth oxides
in the country.