American Rare Earths Orders Key Equipment, Begins Test Mining at Halleck Creek

Project Progress and Strategic Importance

American Rare Earths (ASX, ARR) has announced significant advancements at its Halleck Creek Rare Earths Project in Wyoming, USA. The company is conducting a series of mineral processing optimisation tests aimed at increasing recoveries of magnet rare earth elements, a critical step toward unlocking the project's full potential. These efforts are complemented by the ordering of long-lead time equipment for a demonstration plant and the commencement of test mining at the Cowboy State Mine, a key site within the project.

Optimisation Testing and Technical Enhancements

The optimisation program involves testing multiple comminution methods; such as Vertical Roller Mill, High Pressure Grinding Rolls, and Air Classifier techniques; to reduce the proportion of fine particles that can negatively impact mineral separation efficiency. Additionally, the beneficiation circuit is being refined, with a focus on magnetic separation technologies like Induced Roll Magnetic Separators (IRMS), which have shown promising results in isolating allanite, the rare earth host mineral.

Further primary separation methods, including Reflux Classifier Concentrators and Magnetic Drum separators, are under evaluation to enhance operational efficiencies and potentially reduce processing costs by eliminating intermediate drying steps. Hydrometallurgical processes, particularly impurity removal after leaching, are also being optimised with ongoing testing at SGS’s laboratory in Canada.

Demonstration Plant and Test Mining

To support these technical advancements, American Rare Earths has ordered two full-scale IRMS units expected to arrive in early 2026. These units will form the backbone of the demonstration plant, which will showcase the mineral processing flow-sheet at a larger scale and provide critical data for future feasibility studies.

Test mining is underway to extract approximately 3,200 tonnes of ore, not only to supply bulk samples for optimisation tests but also to provide feedstock for the demonstration plant. This dual-purpose approach maximises operational efficiency and accelerates project development.

Implications for Project Timeline and Market Position

The additional optimisation work extends the timeline for the Cowboy State Mine Pre-Feasibility Study (PFS), a vital milestone that underpins the technical and economic viability of the project. While this introduces some schedule uncertainty, it also de-risks the project by ensuring a robust and optimised processing flow-sheet. The demonstration plant will further validate these processes, positioning Halleck Creek as a cornerstone for U.S. rare earth supply independence amid growing geopolitical and supply chain concerns.

American Rare Earths’ commitment to environmentally responsible mining and collaboration with U.S. government R&D initiatives underscores the strategic importance of Halleck Creek in securing critical minerals essential for defense, advanced technologies, and economic security.