Search Minerals' proprietary multi-stage processing is designed to deliver high-throughput, low-cost production while minimizing environmental impact. The process is as follows:

Primary Processing

Materials extracted from mine sites undergo Magnetic Concentration (MC), consisting of crushing and grinding the materials and feeding them into magnetic separation devices. This includes Low Intensity Magnetic Separation (LIMS) to separate magnetite, Wet High Intensity Magnetic Separation (WHIMS) to extract the majority of the rare earth elements as a magnetic concentrate, and finally the remaining portion which includes non-magnetic material such as zirconium and hafnium. Once separated, all of these materials can undergo further processing to enter into the supply chain.

Search's primary processing produces dry stackable mine tailings, minimizing environmental impact compared to traditional separation processes.

Secondary Processing

Once primary processing has created the magnetic rare earth concentrate, secondary processing can begin. This begins with Search's patented Direct Extraction (DX) process, which uses a series of hydrometallurgical leaching tanks to purify rare earth concentrate into rare earth oxides (REOs). Next comes Solvent Extraction (SE), which separates the rare earth oxides into individual oxides of permanent magnet material. Finally, metals alloy production takes place, converting the oxides into useable metals for the supply chain.

Search's secondary processing products dry stackable hydrometallurgical residue, minimizing environmental impact compared to traditional separation processes.

Here is an overview of Search's processing activities:

Learn more about Search's Primary Processing
Learn more about Search's Secondary Processing
Learn more about the environmental benefits of Search's processing technology