Name of the Project
Phalaborwa Rare Earths Project.

Location
Limpopo, South Africa.

Project Owner/s
London-listed Rainbow Rare Earths (85%).

Rainbow Rare Earths signed an agreement with phosphate mining company Bosveld Phosphates in June 2023 to ensure it obtains 100% ownership of the Phalaborwa project. 

Upon completion of a definitive feasibility study (DFS), the unincorporated joint venture (JV) will be transferred into an incorporated JV company and, at Rainbow’s election, Bosveld will transfer all assets required for the project into that company. 

Project Description
An interim economic study released in December 2024 proposed a project life of 16 years – two years longer than the one envisaged in the October 2022 preliminary economic assessment (PEA) – processing an average of 2.2-million tonnes of phosphogypsum a year.

The overall recovery rate of magnet rare-earth elements remains the same as that of the PEA, at 65%, based on the pilot campaign undertaken from 2023 to 2024, with about 1 900 t/y magnet rare earth oxide (REO) production.

The interim economic study represents a much higher level of confidence in the processing flowsheet prior to separation, and capital and operating cost estimates, than those of the PEA.

In addition to confirming the robust economics of Phalaborwa, the interim economic study has highlighted several areas for further operating and capital cost optimisation, which will be done in parallel with the ongoing rare earth separation testwork.

In November 2025, Rainbow Rare Earths advanced the project by confirming solvent extraction (SX) as the final separation method for producing high-purity REOs. 

The decision followed a detailed review of alternative separation technologies and enables the company to lock in the project’s definitive flowsheet ahead of construction. The SX circuit will use a streamlined arrangement of about 75 mixer-settlers to produce separated neodymium/praseodymium (NdPr) oxide, and a mixed medium- and heavy rare-earth carbonate – samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium and yttrium (SEG+) – known as SEG+. 

The project’s economic outlook has strengthened considerably following a dramatic surge in the price of yttrium, which is now included in the SEG+ basket. Phalaborwa is now expected to produce about 213 t/y of yttrium oxide as part of its mixed heavy rare-earth output. 

Potential Job Creation
Not disclosed in the interim study.

Net Present Value/Internal Rate of Return
When calculated on the same basis as the October 2022 PEA, the interim economic study delivers an after-tax net present value (NPV), at a 10% discount rate, of $611-million, in line with the comparable PEA NPV of $627-million.

Capital Expenditure
The interim economic study provides an updated, upfront capital cost of $326.1-million, which is lower than the PEA capital cost of $295.5-million, adjusted for inflation.

Planned Start/End Date
Rainbow remains on track to start construction in 2027, with first production targeted for 2028.

Latest Developments
Rainbow Rare Earths has announced that its recently commissioned large-scale pilot plant is operating the optimised Phalaborwa primary flowsheet in line with expectations and has successfully produced about 2 kg of a high-grade mixed rare earth hydroxide, a commercial product.

The company has previously noted that the mixed rare earth product produced by the primary flowsheet has a higher grade than the industry norm, being about 55% TREO, versus the Chinese specifications for a mixed rare-earth carbonate at about 42% to 44% TREO.

The production of this high-grade product has been confirmed as a suitable feed stream into the planned SX separation circuit to produce NdPr oxide and an SEG product that is rich in medium and heavy rare earth elements (REE), each at +99.5% purity.

By delivering these separated products, Rainbow intends to capture more of the value chain by going further downstream than many REE projects.

Key Contracts, Suppliers and Consultants
ANSTO Minerals (plant processing testwork); K-Tech Inc (REO separation technology and partner in developing plant processing flowsheet, managing the back-end of the pilot plant at its US facility); Mintek (managing plant front-end in South Africa); and METC Engineering (production of the PEA and engineering work for the DFS).

Contact Details for Project Information
Tavistock Communications, on behalf of Rainbow Rare Earths, tel +44 20 7920 3150 or email rainbowrareearths@tavistock.co.uk.