This blog post was originally published in 2023 and was updated in 2026.
The Saskatchewan Research Council (SRC) is laying the foundation for a North American rare earth element (REE) supply chain with the development of a first-of-its-kind, fully integrated Rare Earth Processing Facility (REPF), complete with hydrometallurgy, separation and metal smelting stages.
Currently in its early commissioning stages and with full operations on the horizon in 2027, SRC’s state-of-the-art, minerals-to-metals facility is positioned to stimulate Canada’s resource sector and showcase the variety of innovative technologies designed in-house by SRC experts.
Most notable among these technological achievements are SRC’s proprietary solvent extraction (SX) cells, which were designed and manufactured in-house at an SRC-operated fabrication facility. This commercial-scale, multi-year fabrication project served as the backbone of the Facility’s Solvent Extraction Unit — one of two new buildings that have been purpose-built for the REPF.
The Solvent Extraction Unit building houses more than 400 custom-made SX cells, which were built into modular units known as “batteries” and arranged into banks. These cells will separate select REEs, helping to increase their value before they advance to the metal smelting stage.
With the installation of these cells complete and several patents pending on key aspects of the equipment and processes, SRC is now one of a select few entities in the world with the capability to design and deliver this leading-edge SX technology. What makes SRC’s approach unique is the addition of machine learning and artificial intelligence (AI) to enable more efficient, automated operations, which reduces costs, labour and processing time, while enhancing overall system performance.
This innovation supports the development of a secure, domestic rare earth supply chain, accelerating industry growth in North America.
Up to the Challenge: Designing and Fabricating In-House Technology
SRC’s proprietary solvent extraction cell fabrication project was born out of necessity, after China restricted exports of the REE processing equipment that SRC’s team had planned to use in the facility.
“When we started this project back in 2020, our plan was to procure these cells internationally, but a new export law in that jurisdiction restricted exports of the REE processing equipment,” said Mike Crabtree, SRC President and CEO.
“We tried to get the cells from other countries,” he said, “but ultimately, we thought we should do what we do best as a research and technology organization and design and build the solvent extraction cells ourselves."
SRC’s industry-leading mineral processing and rare earth element experts went to work designing, testing and manufacturing the SX cells in-house, which were fabricated from locally-sourced PVC material that was welded into shape. To address the challenges of PVC welding, SRC developed semi-automated welding equipment to improve performance and reduce physical demands.
"Saskatchewan has a rich history in equipment development, innovation and manufacturing for the agriculture and mining industries, so developing this technology for REEs was a natural next step," said Erin Herman, director of REE Commercial with SRC’s Rare Earth Element Division. "SRC is fortunate to have in-house experts in REE separation, as well as machine learning and AI, so this work was something the Council was ideally suited for."
Along with the manufacture of the SX cells, SRC’s team developed an AI algorithm-driven control system that detects system imbalances and ensures overall efficiency.
“Solvent extraction cells are well known for causing difficulties in attaining and maintaining critical steady state conditions, which are required in order to meet the strict quality standards in industry for separated rare earth elements,” noted Herman. “SRC’s proprietary, computerized control system, in conjunction with the solvent extraction cells, will run the cells, reducing operator intervention and optimizing performance.”
This system includes the necessary automation components built into the SX cells, making the algorithm-driven control functions possible. In addition to the control system, SRC developed another proprietary innovation – a patent-pending fluid level sensor that can generate specific process information data, which is critical to the performance of the SX cells and control system.
As a key co-developed product, SRC also developed its own design for mini-SX cells and micro-SX cells that are used for pilot testing, with cell sizes ranging from 250 millilitres up to four litres. These small, bench-scale cells mirror the functionality and performance of the commercial cells – enabling effective process validation and optimization – and include SRC-designed control systems and testing apparatus.
“The experience gained and the equipment developed in this project makes SRC one of the leading rare earth solvent extraction companies in the world,” said Crabtree.
“Through this project, we’ve proven that SRC can model and design, provide bench and pilot-scale testing and validation, and fabricate commercial equipment,” he said. This also includes associated sensors and control systems — either as stand-alone services to clients or as an all-in-one package.
Building the REE Supply Chain
Saskatchewan’s long history of mining critical resources makes the province a unique leader in REE processing.
“Canada has some of the largest known reserves and resources, measured and indicated, of rare earths in the world,” said Dr. Muhammad Imran, Vice-President and Chief Technology Officer in SRC’s REE Commercial Division. “So, it makes sense to kickstart the industry where the resource availability is.”
SRC’s Rare Earth Processing Facility consists of three crucial components: the Monazite Processing Unit, the Solvent Extraction Unit and the Metal Smelting Unit.
Solvent extraction is a necessary step that makes REEs more valuable. Once this stage is complete, the separated rare earths can be converted into metal in the Metal Smelting Unit.
“Rare earths are not really different from other mining sectors when you look at the raw material,” said Dr. Imran. “REEs are separated from impurities in the Monazite Processing Unit. Once that process is complete, the rare earths need to be separated from each other and that’s where the Solvent Extraction Unit comes in.”
At SRC’s facility, the in-house fabricated SX cells will separate the rare earths into five products: medium/heavy mixed REEs, lanthanum/cerium carbonate, a neodymium/praseodymium (NdPr) mixture, and pure terbium and dysprosium. The NdPr product then undergoes further processing in the Metal Smelting Unit to transform it into NdPr alloy metal.
This unit contains in-house developed, innovative metal smelting technology to produce REE metals. SRC marked a North American “first” in the summer of 2024, when this technology produced REE metals at commercial scale.
As it looks to reach fully integrated operation in 2027, SRC has already secured a client to purchase the majority of the REPF’s annual production and continues to seek out domestic and international clients, supporting broader market development and diversification opportunities.
The Skills and Expertise for the Job
With nearly 80 years of innovation experience, SRC has the proven safety record and expertise needed to handle the intricacies of REE processing. As Canada’s second largest research and technology organization, SRC has unparalleled experience in mining and mineral recovery.
“REE processing is quite complex and includes the use of chemicals, large quantities of water and skilled techniques. The process must also follow strict environmental regulations,” said Dr. Imran. "You need to have the expertise and the capabilities and that’s where SRC really shines.”
From the safe operation and decommissioning of a SLOWPOKE-2 research reactor to the management of Project CLEANS — a multi-year project to assess and remediate 37 abandoned uranium mines — SRC regularly works closely with industry, regulators and communities.
“The work we are doing has a substantial impact on the overall economy of Saskatchewan,” said Dr. Imran. “Those economic benefits are in the form of jobs, improved productivity, process optimization and delivery of new concepts to commercial applications.”
