REalloys Inc. (NASDAQ: ALOY) announced the successful demonstration of a patent-pending hydrofluoric-acid-free fluorination process for producing metallization-grade rare earth fluorides from rare earth oxides. This innovation eliminates one of the most hazardous chemicals traditionally used in rare earth processing, potentially enabling safer and more scalable rare earth metallization in North America.
Independent laboratory testing confirmed the HF-free process produced fluoride with a final oxygen content of just 0.34 wt%, a level consistent with rare earth fluoride feedstock used in industrial rare earth metal production. Metallization-grade rare earth fluoride feedstocks typically require oxygen levels below 1 wt%, making these results significant for downstream applications.
Hydrofluoric acid is widely considered one of the most hazardous and difficult chemicals used in industrial metallurgy, remaining a standard reagent in conventional rare earth fluorination processes widely used in China and other rare earth processing centers. Its extreme toxicity and corrosiveness require specialized containment systems, highly controlled handling procedures, and extensive environmental and regulatory compliance measures that significantly increase operating costs and create substantial safety and environmental risks.
"Hydrofluoric acid has been necessary for rare earth metallization, until now," said Lipi Sternheim, Chief Executive Officer of REalloys. "We believe this breakthrough can significantly reduce the environmental burden, safety risks, and costs traditionally associated with this critical step of rare earth processing while helping enable cleaner rare earth metal production in the United States as an alternative to the environmentally intensive processing methods that dominate rare earth production in China."
In addition to improving safety, the company believes the HF-free process has the potential to reduce operating costs, simplify plant infrastructure, lower environmental and regulatory burdens associated with hydrofluoric acid handling, and support more resilient rare earth processing supply chains. REalloys has filed patent applications covering aspects of the HF-free fluorination chemistry and process design, forming part of the company's broader portfolio of rare earth metallization technologies.
Rare earth fluorides are a critical intermediate used in the production of rare earth metals, including dysprosium, terbium, and neodymium, that are essential for high-performance permanent magnets used in F-35 fighter aircraft, missile systems, radar platforms, aerospace systems, electric vehicles, robotics, and advanced computing infrastructure. China currently dominates key midstream rare earth processing steps, including fluorination and metallization required to produce heavy rare earth metals used in high-performance magnets for missile guidance, radar systems, and other defense technologies.
By eliminating the need for hydrofluoric acid in this critical step, REalloys' HF-free fluorination process could help enable scalable rare earth metal production in North America and strengthen domestic supply chains for critical defense materials. The company's broader strategy includes building a platform to scale North American heavy rare earth midstream separation, refining, and metallization capabilities, creating a coordinated system that processes and converts heavy rare-earth materials into high-purity products. More information about the company is available at https://www.realloys.com, and investors can find additional disclosure information through the company's SEC filings available at https://www.sec.gov.
