Rice-validated FJH method advances U.S. rare-earth refining

Rice University researchers have published peer-reviewed results demonstrating that Flash Joule Heating (FJH) combined with chlorination can recover rare earth elements from end-of-life magnets with high efficiency.

The study, led by Professor James Tour and published in Proceedings of the National Academy of Sciences (Sept. 29, 2025), shows a pathway that avoids conventional acid digestion and wastewater, delivering higher yields and faster processing from magnet waste streams.

Metallium Ltd., which holds an exclusive license to commercialize this FJH application, said it will integrate the method into its pilot-scale operations in Texas through its U.S. unit, Flash Metals USA. Executives emphasized the pilot as the next step to translate lab-scale chemistry and thermal processing into an industrial prototype capable of scaling rare-earth recovery.

Metallium’s FJH platform is already aimed at low-carbon recovery of critical and precious metals - including gallium, germanium, antimony and gold - from concentrates, e-waste and refinery scrap. The company plans to commission its first commercial site in Texas in December and is expanding demonstration capacity while pursuing partnerships to secure feedstocks and downstream processing.