$104M Utah heavy rare earth expansion targets materials for six million EVs yearly

China dominates global heavy rare earth processing, creating a major challenge for U.S. manufacturers that rely on the materials for permanent magnets used in electric vehicles, defense systems, robotics, and other advanced technologies. Energy Fuels aims to narrow that gap by expanding its White Mesa Mill in Utah into one of the few commercial facilities in North America capable of producing both light and heavy rare earth oxides, strengthening the company’s planned mine-to-magnet supply chain. Utah rare earth expansion The White Mesa Mill already produces up to 1,000 metric tons of separated neodymium-praseodymium (NdPr) oxide each year. Energy Fuels has now started construction on an expansion that will add commercial production of heavy rare earth oxides, including terbium and dysprosium, by the end of 2027. Production of samarium, europium and gadolinium oxides is scheduled to follow in 2028. Those heavy rare earths improve the heat resistance and magnetic performance of permanent magnets used in electric motors, military systems and other high-performance applications. Commercial processing capacity outside China remains limited, making the expansion strategically important for Western manufacturers. President and CEO Ross Bhappu said the company has already demonstrated the technology through pilot operations and is now ready to move into commercial-scale production. He said producing both light and heavy rare earth oxides will set Energy Fuels apart as it builds an integrated mine-to-magnet business through its planned acquisitions of Australian Strategic Materials and Vacuumschmelze. Once complete, the expansion will give the Utah facility annual capacity to produce approximately 20 metric tons of terbium, 120 metric tons of dysprosium, 140 metric tons of samarium, 20 metric tons of europium and 140 metric tons of gadolinium oxides. Mine to magnet Energy Fuels designed the expansion around expected feedstock from the Donald Project in Australia, which could begin producing monazite concentrate in 2028 following a final investment decision expected later this year. After processing at White Mesa, the rare earth oxides will move to Australian Strategic Materials’ facilities in South Korea for conversion into rare earth metals and alloys. Those materials are then expected to supply Vacuumschmelze’s magnet manufacturing plant in Sumter, South Carolina, creating an integrated supply chain that links mining, processing, alloy production and finished magnet manufacturing across allied nations. The company also plans to install a processing circuit for mixed rare earth carbonates, allowing the mill to process a broader range of feedstocks while producing uranium and rare earth oxides simultaneously. Larger plans ahead Energy Fuels estimates the current expansion will cost about $104 million. Government loans and grants are expected to cover much of the project, while the company plans to fund the remaining investment from its existing cash reserves. Another White Mesa expansion is planned for 2029 to significantly increase production of both light and heavy rare earth oxides using material from projects in Australia, Madagascar and Brazil alongside third-party supplies. According to Energy Fuels, the fully integrated mine-to-magnet network could eventually produce about 15,700 metric tons of permanent magnets annually. The company says that output would be enough to supply magnets for up to six million electric or hybrid vehicles each year, around four million humanoid robots and thousands of offshore wind turbines, underscoring the scale the company hopes to achieve as it builds a Western alternative to China’s rare earth supply chain.Recommended ArticlesGet the latest in engineering, tech, space & science - delivered daily to your inbox.Aamir is a seasoned tech journalist with experience at Exhibit Magazine, Republic World, and PR Newswire. With a deep love for all things tech and science, he has spent years decoding the latest innovations and exploring how they shape industries, lifestyles, and the future of humanity.