Closing the U.S. Rare Earth Processing Gap With China
REACT for Conventional Ores: Closing the U.S. Rare Earth Processing Gap
By Ozzy Services
The U.S. Rare Earth Challenge
America holds rich rare earth deposits — Bear Lodge in Wyoming, Mountain Pass in California, Round Top in Texas — yet the nation still relies heavily on foreign refining to produce usable materials for magnets, motors, and electronics.
Why? Because current domestic leaching and precipitation methods can’t maintain consistent chemistry or yield.
Meanwhile, China’s integrated roasting-based flowsheets hit 95%+ recovery rates using kilns and scrubbers operating at 300–600°C — but at enormous energy and environmental costs.
Ozzy Services built REACT to solve this problem without roasting.
REACT brings refinery-grade process control to rare earth leach circuits — in real time.
Introducing the Patented REACT System
The REACT System (Real-Time Elemental Assay & Conditioning Technology) is a modular, AI-driven conditioning skid that stabilizes slurry quality between leaching and precipitation.
It replaces manual pH adjustments and off-line assays with continuous measurement, feedback, and smart routing.
In short: REACT transforms raw, variable slurry into clean, on-spec feed ready for precipitation — just like China’s systems, but without the heat, emissions, or million-dollar kilns.
How It Works: Real-Time Optimization Without Roasting
REACT’s architecture mirrors the reliability of gas custody-transfer skids — redundant sensors, flow conditioning, and feedback loops — but applied to liquid-solid mineral streams.
Step-by-step workflow:
Buffer Tank: Agitation and microdosing bring slurry pH into a controlled range.
Hydrocyclone Cascade: Removes coarse fines and filters down to 5–15 microns.
Conditioning Section: Static mixers and flow straighteners create a stable matrix for accurate readings.
Dual Sensor Legs: Each includes inline XRF, thorium gamma detectors, turbidity probes, and temperature sensors.
AI Decision Engine: Integrates live data to determine if slurry moves forward or loops back for reconditioning.
If thorium spikes above safe limits, REACT automatically coagulates it and diverts solids to a dedicated thorium holding tank, keeping the system DoD and EPA compliant.
Smart Control and AI Integration
At the heart of REACT lies an AI logic layer that continuously evaluates slurry chemistry.
It applies solubility product constants (Ksp) to predict precipitation outcomes — adjusting microdosing and routing in real time.
If one sensor leg drifts, REACT isolates and self-cleans it while maintaining uptime.
The result is a self-correcting feedback loop capable of maintaining <2% deviation in pH, turbidity, and REE concentration.
“REACT doesn’t wait for lab results. It measures, learns, and corrects every minute of every run.”
— Ozzy Services Engineering Team
Proven Advantages Over Conventional Systems
MetricConventional Leach/PrecipitationREACT SystemEnergy UseHigh — roasting at 300–600°CLow — ambient operationCapital Cost$5–10M for kilns/scrubbers~$625K for pilot skidYield50–80%95%+Waste ReductionModerate25%+ reductionThorium ManagementManualAutomated, inline gamma detection
REACT achieves the same recovery efficiency as China’s roasting method, but with far lower environmental and capital costs.
Scalable and Portable by Design
Each REACT unit is skid-mounted and flanged, making it transportable from pilot plants to full-scale facilities.
It’s designed for 1–10 tons per day pilot operations and scales to 100+ tpd industrial modules without redesign.
That means shorter development timelines, easier permitting, and flexible deployment across U.S. rare earth projects — from Wyoming to Texas.
One skid, infinite scalability.
The Bigger Vision: Securing America’s Supply Chain
Ozzy Services believes that critical mineral independence begins with smarter processing, not just more mining.
By merging chemical engineering with AI-driven control, the REACT system turns every rare earth plant into a data-rich, continuously optimized operation.
Key Impact Areas:
Strengthens the U.S. REE refining base
Enables cost-effective, modular deployment
Reduces emissions and thorium waste
Attracts investment through patent-backed innovation
“REACT is more than a product — it’s a bridge between U.S. innovation and industrial resilience.”
See the Bigger Picture
Want to learn how REACT is changing the future of rare earth processing in America?
Visit our main overview:
👉 The Rare Earth Gamechanger — REACT System by Ozzy Services
About Ozzy Services
Ozzy Services develops field-ready modular systems that close the gap between raw extraction and precision refining.
Our patented REACT technology brings real-time analytics, automation, and compliance to rare earth element processing across multiple feedstocks.
