American Rare Earths Limited Achieves 85% Rare Earth Recovery and Slashes Impurities at Wyoming’s Cowboy State Mine
Wednesday, July 9, 2025
at
9:11 am
American Rare Earths Limited’s latest atmospheric tank leach tests achieved up to 85% rare earth extraction with significantly lower impurities. This breakthrough enhances the economic viability of its Wyoming project, bringing the company one step closer to producing cost-efficient, domestic rare earths and reducing reliance on imports.
American Rare Earths Limited has advanced its Halleck Creek Rare Earths Project in Wyoming by reporting promising results from an extensive leach testing campaign conducted on ore from the Cowboy State Mine. The company completed 25 tests at an SGS laboratory in Canada using sulfuric acid as the lixiviant. Under carefully controlled conditions, tests revealed high recoveries for light rare earth elements – with praseodymium and neodymium leach recoveries reaching 85% and 84%, respectively. Encouraging recoveries were also recorded for heavy rare earths, with terbium at 52% and dysprosium at 46%. Additionally, the levels of key impurities such as iron and aluminum in the leachate were significantly reduced compared to earlier tests, marking a crucial step for the project’s cost efficiency and process de-risking.
The testing identified atmospheric tank leaching as the preferred method due to its favorable balance of energy, reagent efficiency, and overall reduced costs. In one highlighted test (labelled AL16), the feed comprised 80% unaltered concentrate produced through gravity spiral separation and induced roll magnetic separation, with the remaining 20% being fines processed from comminution. Conditions during the test included an acid dosage of 400 kg per tonne, an 8‑hour retention time at 90°C, and a particle size adjusted to 100% passing 270 mesh. These parameters contributed to the impressive extraction rates noted across the rare earth suite while concurrently limiting the extraction of impurities. The next phase will see SGS carrying out scoping impurity removal tests, further refining the processing flow sheet for the upcoming Pre‑Feasibility Study.
The robust leach recoveries and lower impurity levels suggest favorable processing outcomes that could lower energy consumption and operating costs—a positive indicator for the project’s economic viability and strategic position in reducing U.S. reliance on imported rare earths. From a market perspective, the comprehensive de-risking of the metallurgical process is likely to be viewed as a bullish sign. However, some caution remains regarding the capital intensity of alternative leach methods and the ongoing need for environmental and permitting studies, which could lead to more cautious sentiment among certain investors.
Overall, the technical advancements at Halleck Creek underscore American Rare Earths Limited’s commitment to optimizing rare earth extraction technology, laying a stronger foundation for progressing its project and contributing to a more secure domestic supply of critical minerals.