Ucore Rare Metals (TSXV: UCU / WKN A2QJQ4) has announced an important formal step toward the commercialization of its RapidSX™ separation technology: The company submitted the final report for Phase 1 of its “Other Transaction Agreement” (OTA) with the US Department of Defense (DoD) to the US Army Contracting Command – Orlando. Included in the documentation are a Final Demonstration Report and a concluding techno-economic analysis (TEA). Both documents summarize the work at Ucore’s RapidSX™ Commercialization and Demonstration Facility (CDF) in Kingston, Canada, and are intended to provide transparent documentation of the results achieved in Phase 1.
At its core, the goal is to demonstrate that RapidSX™ can more efficiently transfer solvent extraction—as commonly used in the industry for years—into an industrial environment. Ucore positions its proprietary RapidSX™ technology as an alternative to the conventional process, which, according to the company, has so far been the only technology used commercially on a large scale worldwide for the separation of rare earths. Separation of elements such as neodymium and praseodymium or dysprosium and terbium is considered demanding because it requires precise control of complex process steps.
Ucore and RapidSX: What Phase 1 Was Intended to Demonstrate
According to the announcement, the submitted report covers several thematic areas: these include the project’s objectives and scope, the comparison with CSX (conventional solvent extraction), and ongoing improvements implemented at the RapidSX™ facility during the demonstration phase. Ucore emphasizes that RapidSX™ is based on the proven chemistry of solvent extraction but implements this approach in a “smarter” and more space-efficient manner.
A central point is the process control: RapidSX™ is designed to reach a state of chemical equilibrium faster—and with a smaller plant configuration. This leverage is crucial for scaling a separation technology, as a smaller footprint and modular design can facilitate implementation in a commercial environment. As reported, tons of realistic feedstock were also processed: a “heavy mixed rare earth oxide” (MREO), which is a mixed oxide starting material with a focus on heavy rare earths.
Another focus is the evaluation regarding specific elements explicitly named by Ucore: in addition to heavy rare earths, samarium and gadolinium are highlighted – metals described in the announcement as relevant for defense, green energy technologies, electromobility, and new industries. This content is supplemented by the presentation of milestones, key performance indicators, “lessons learned,” and a summary of the benefits for the US side and other stakeholders.
6,000 Hours of Runtime and Comparative Data: Ucore Reports from CDF Operations
The outstanding results of the final report focus on the direct comparison of RapidSX™ with conventional CSX. To achieve this, Ucore not only operated the RapidSX™ demonstration plant but also conducted parallel tests in a neighboring CSX pilot plant, which was also built by the company. This is intended to allow for a comparison under the most similar conditions possible.
According to Ucore, approximately 6,000 operating hours were completed on the RapidSX™ demonstration plant in Phase 1—specifically in a simulated commercial production environment. As a result, thousands of liters of various chloride products were produced, including PrNd, SmEuGd, Sm, Gd, Tb, and Dy; additionally, there were smaller batches of oxide products. Ucore also points to a large database: more than 10,000 comparison points regarding recovery and purity compared to conventional solvent extraction were recorded. According to the company, these data demonstrate that RapidSX™ functions under the planned operating parameters while supporting capital-efficient implementation through scalability and modularity.
CEO Pat Ryan places the step in a strategic context: the processing and separation of rare earths is a field in which supply chain independence is increasingly viewed as security-relevant. Ucore sees RapidSX™ as a technology-driven approach to offset existing disadvantages compared to state-supported processing capacities—particularly in the People’s Republic of China.
Phase 2 Already Underway: Commercial RapidSX Machine in Louisiana as the Next Milestone
Parallel to the announcement of the Phase 1 completion, Ucore refers to the status of Phase 2: this phase of the agreement was finalized in May 2025 and is already being implemented, according to the company. Of 20 milestones, 5 have currently been reached. Phase 2 is intended to culminate in the construction, commissioning, and demonstration of a commercial-scale RapidSX™ machine at the company’s site in Alexandria, Louisiana—the “Louisiana Strategic Metals Complex.”
Ucore describes the setup as a modular series approach: several RapidSX™ machines, connected in series, are intended to form the first stage of a processing capacity of 2,500 tons per year of “total rare earth oxide” (TREO). The announcement thus specifies a clear scale by which the transition from demonstration to commercial operation is to be measured.
At the same time, Ucore announced that it will only publish more detailed information on the project results and the TEA after formal acceptance of the final report by the US Army office—this is expected “in the coming weeks.” With a view to long-term corporate planning, Ucore also points to further building blocks: in addition to the processing technology, the strategy also includes future plants in Canada and Alaska, as well as the 100% controlled Bokan-Dotson Ridge project on Prince of Wales Island in Southeast Alaska.
This solidifies a timeline for Ucore that documents the technical maturity and data from Phase 1, while Phase 2 is intended to simultaneously prepare the leap to commercial scale—with a clearly defined focus on the separation and processing of rare and critical metals in the United States.
