Sustainable and Energy-Efficient Production of Rare-Earth Metals via Chloride-Based Molten Salt Electrolysis

Neodymium metal is a critical component of rare earth magnets, essential for electric vehicles and the green energy transition, but its production has severe environmental impacts across its mining, separation, purification, and metal electrowinning steps. Specifically, conventional neodymium electrowinning in oxyfluoride molten salts using a consumable graphite anode generates greenhouse gases, e.g., carbon dioxide and perfluorocarbon (PFC). We propose an alternative chloride-based molten salt electrolysis process utilizing a novel dimensionally stable anode (DSA). Our process lowers the specific electrical energy consumption compared to the state of the art, while producing reusable chlorine gas and eliminating direct CO₂ and PFC emissions. Chloride-based molten salt electrolysis of NdCl₃ (1.65 M) added to a LiCl–KCl eutectic (45:55 wt %), while using a RuO₂-coated DSA enables high Coulombic efficiency (>80%), low specific energy consumption (2.3 kWh/kg-Nd), and excellent electrowon Nd product purity (>97 wt %). Life cycle analysis, excluding the common input feedstock (Nd₂O₃), shows that the global warming potential for the proposed chloride-based electrolysis approach is 5 kg CO₂ equivalent, compared to 9–16 kg CO₂ equivalent for the conventional process, representing a 44–69% reduction in CO₂ emissions.