In this interview, Less Common Metals (LCM) shares insights into its role within the SUPREEMO project and the challenges of refining rare earth alloy production. Through a series of questions, LCM explains how its expertise in molten salt electrolysis supports Europe’s goal of building a resilient, self-sufficient rare earth value chain.
- Why did you join the SUPREEMO project and what’s your role?
Less Common Metals (LCM) joined the SUPREEMO project because we recognise the strategic importance of establishing a resilient, competitive, and fully European rare earth value chain.
As one of the few commercial producers of rare earth alloys and metals in the western world outside of China, LCM is uniquely positioned to support the SUPREEMO consortium in bridging the gap between rare earth oxide production and magnet manufacturing. Our specific role in SUPREEMO is to lead the process of metallising rare earth oxides into high-purity rare earth metals and alloys, primarily neodymium and praseodymium (NdPr), dysprosium (Dy), and terbium (Tb), using our expertise in molten salt electrolysis and alloy production.
- What were the key challenges you encountered in optimising efficiency for REA (Rare Earth Alloy) production?
One of the main challenges in optimising the production of Rare Earth Alloys (REA) is ensuring chemical consistency and homogeneity across different batches. The variability in oxide feedstock, which arises from the differing mineral compositions of deposits in Norway, requires careful adjustments to the electrolyte composition and reduction conditions. Additionally, innovations that are successful at the laboratory scale in the electrolysis process often face difficulties when scaled up. Transitioning to pilot-scale production introduces complexities in maintaining repeatability, yield, and purity. Therefore, it is essential to finely tune process parameters to ensure a reliable and high-quality alloy output.
- Do you have already experience with commissioning high-temperature electrolysis pilots? How do you validate the efficiency of the design, and what metrics do you prioritise?
LCM has extensive experience in designing, building, and commissioning high-temperature electrolysis units for both development and full-scale production. We have successfully operated molten salt electrolysis systems for a range of rare earth elements, continuously refining our processes over decades of industrial application. To validate the efficiency of each design, we prioritise key metrics such as current efficiency, energy consumption, impurity levels in the final metal, and throughput and batch reproducibility, which reflect overall process stability and scalability.
- How do you ensure that innovations in electrolysis cell design translate effectively into pilot-scale systems?
We, at LCM, adopt a systematic, staged scale-up approach by validating new designs at laboratory scale under controlled conditions, focusing on key parameters such as electrode stability, current distribution, gas evolution behaviour, and electrolyte compatibility. Successful concepts are then implemented in modular pilot-scale units that replicate industrial conditions, providing a critical bridge toward reliable full-scale production.
- How do you see the future of the SUPREEMO project?
We see SUPREEMO as a transformative initiative for Europe’s rare earth sector. This project not only connects upstream ore processing with downstream magnet production but also establishes a foundation for European self-sufficiency in critical materials.
