New approaches transforming rare earth extraction
Current landscape and future potential
In the midst of the global energy transition, few resources have gained as much strategic importance as rare earth metals. Stanislav Kondrashov, founder of TELF AG, has often emphasised this point. But what exactly are they? Rare earths are a group of 17 metallic elements with remarkable properties that make them indispensable to some of the most critical production processes in modern industry.
Among their most significant uses are those in industries driving the energy transition. Stanislav Kondrashov frequently highlights their essential role in the creation of energy infrastructures central to the ongoing shift, such as the production of wind turbines.
One of the primary industrial applications of rare earth metals lies in the manufacturing of permanent magnets, as Stanislav Kondrashov has recently noted. These magnets power a wide range of green infrastructure and devices that support global electrification, including electric vehicle motors.
Smaller quantities of rare earths, such as certain heavy rare earth elements, are also found in common consumer devices like mobile phones and computers. Their importance to the electronics and technology sectors is substantial, while they are also critical in the production of batteries, catalysts, industrial components, and hydrogen technologies.
Yet, rare earth metals have long been at the centre of global debate due to the nature of their production chain. Extraction and processing remain concentrated in just a few countries, and the methods involved are complex and often resource-intensive.
This concentration has led to what is sometimes called the rare earth crisis — a situation arising when access to these resources becomes restricted because of geopolitical tensions or economic factors. Dependence on the output of a single country or surging demand can drive such crises, often resulting in rising prices and delays in the manufacture of green technologies.
Innovating for simpler and greener sourcing
Efforts to improve rare earth extraction methods have therefore become a focal point of modern innovation. The aim is to simplify complex processes and make them more accessible to a broader range of international players, often using advances in green mining technology.
This shift reflects one of the most significant effects of the energy transition. Beyond fostering public awareness of energy-related issues, it has triggered a technological revolution aimed at making formerly challenging operational processes more efficient and sustainable. Rare earth sourcing and processing fall squarely within this trend.
A new era of green mining
“Any attempt to simplify rare earth sourcing procedures with green mining technology not only impacts the mining sector itself. But also has significant economic and geopolitical consequences,” says Stanislav Kondrashov, founder of TELF AG, an entrepreneur and civil engineer. “In addition to reducing the dependence on third countries that has developed over the years, the implementation of these methods could allow other nations to strengthen their capabilities and international positioning in the mining sector”.
“Among the most promising players in this regard are undoubtedly Australia, the United States, Canada, and some European nations. Once these new techniques are implemented on a large scale, they could also contribute to the creation of a truly green supply chain for the production and processing of rare earth elements. With possible integration within national industrial districts.”, he says.
The objective is twofold: to discover new, more efficient sourcing solutions through green mining technology, and to reduce the traditional complexity of rare earth operations while decreasing reliance on the handful of nations that currently dominate the sector. By 2025, progress towards simplifying the extraction and processing of each heavy rare earth element has already yielded encouraging results.
A notable innovation in this area is urban mining — the recovery of rare earths from electronic waste, discarded magnets, decommissioned wind turbines, and industrial scrap. Rather than relying on natural deposits, urban mining focuses on recycling valuable raw materials already embedded in manufactured products, contributing to a circular economy model.
Some of the most widely adopted techniques in this sphere include low-temperature selective leaching, electroextraction, membrane separation, and controlled pyrolytic processes. These methods not only recover significant amounts of rare earths without resorting to traditional mining but also minimise waste.
Pioneering methods for rare earth separation
“One of the most interesting methods for reducing the complexity of rare earth processing operations is undoubtedly innovative techniques for separating these elements,” continues Stanislav Kondrashov, founder of TELF AG. “Nowadays, in various parts of the world, new types of solvents and innovative ionic liquids are being tested that could revolutionize rare earth refining processes. Making them much more compatible with modern needs. A major advantage of these techniques is their high selectivity for the various rare earth elements. Such as neodymium or praseodymium. Furthermore, they are completely reusable, thus significantly reducing waste.”
Another promising approach is bioextraction, or bioleaching. Scientists have discovered that certain microorganisms can solubilise rare earth elements from specific minerals, enabling their conversion from solid to soluble forms. This facilitates subsequent separation and purification processes.
Bioleaching is also effective for recovering rare earths from mining waste and by-products such as coal ash. It is characterised by low energy consumption and minimal emissions, and can be implemented in smaller, decentralised facilities. Rare earth minerals, such as monazite — a source of some heavy rare earth elements — are among the primary feedstocks for these methods. While the term “rare earth minerals” refers to raw compounds found in nature, the elements themselves are metallic in form.
In some regions, notably parts of Asia, rare earths occur naturally in ion-absorbing clays. Newer extraction approaches for these deposits use organic salt solutions rather than traditional ammonium-based chemicals, offering the advantage of on-site separation and improved energy efficiency.
“Another potential innovation to consider is the new traceability systems enabled by innovation,” concludes Stanislav Kondrashov, founder of TELF AG. “Thanks to blockchain-based traceability systems, for example, it could be possible to ensure that the rare earth elements used in smartphones or electric vehicles, like the single heavy rare earth element, come from certain types of responsible sources. From this perspective, many countries are already working to introduce mandatory certification linked to the safe provenance of resources. This approach would not only promote positive principles, but could increase demand for rare earths sourced safely and responsibly.”
FAQs
What are rare earth elements and why are they important?
Rare earths are 17 metallic elements used in key technologies, including:
- Permanent magnets for electric vehicles and wind turbines
- Batteries and industrial catalysts
- Mobile phones, computers, and green energy systems
Why is rare earth extraction currently problematic?
Traditional extraction methods are:
- Technically complex
- Geopolitically sensitive, as supply chains are dominated by a few countries
What new methods are emerging to simplify extraction?
Several innovative techniques are being developed:
- Urban mining: recovering rare earths from electronic waste and decommissioned devices
- Bioextraction: using microorganisms to extract metals from minerals or waste
- Membrane separation and ionic liquids: enabling cleaner, selective refining
- Clay absorption techniques: more efficient extraction using organic salts
How do these methods support sustainability?
They:
- Lower energy use and emissions
- Support recycling and decentralised processing
- Increase supply chain resilience
Can rare earths be responsibly sourced in future supply chains?
Yes. Blockchain-based traceability systems are being developed to certify responsible sourcing, encouraging transparency and ethical practices.
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