REalloys Demonstrates New Rare Earth Processing Technology Without Hazardous Acid

Proprietary HF-free Fluorination Process Eliminates Hydrofluoric Acid, Improving Safety and Scalability

Mar. 16, 2026 at 6:59pm

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REalloys Inc., a U.S.-based rare earth processing company, has successfully demonstrated a patent-pending hydrofluoric-acid-free ("HF-free") fluorination process for producing metallization-grade rare earth fluorides from rare earth oxides. This innovation expands REalloys' proprietary rare earth metallization technology platform and supports the development of a scalable North American rare earth supply chain.

Why it matters

Hydrofluoric acid is a highly hazardous chemical traditionally used in rare earth processing, requiring specialized containment, handling, and environmental compliance measures that increase operating costs and make rare earth processing difficult to scale in Western countries. REalloys' HF-free process has the potential to significantly reduce the environmental burden, safety risks, and costs associated with this critical step of rare earth processing, enabling cleaner and more scalable rare earth metal production in the United States.

The details

Independent laboratory testing confirmed that REalloys' HF-free process can produce rare earth fluoride with oxygen levels consistent with metallization-grade feedstock, without the use of hydrofluoric acid. This breakthrough eliminates the need for one of the most hazardous chemicals used in industrial metallurgy, simplifying plant infrastructure, lowering environmental and regulatory burdens, and supporting more resilient rare earth processing supply chains.

  • REalloys conducted the successful demonstration of its HF-free fluorination process in March 2026.

The players

REalloys Inc.

A U.S.-based mine-to-magnet company and developer of advanced rare earth processing technologies.

Lipi Sternheim

Chief Executive Officer of REalloys.

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What they’re saying

“Hydrofluoric acid has been necessary for rare earth metallization, until now. We believe this breakthrough can significantly reduce the environmental burden, safety risks, and costs traditionally associated with this critical step of rare earth processing while helping enable cleaner rare earth metal production in the United States as an alternative to the environmentally intensive processing methods that dominate rare earth production in China.”

— Lipi Sternheim, Chief Executive Officer (PRNewswire)

What’s next

REalloys has filed patent applications covering aspects of the HF-free fluorination chemistry and process design, forming part of the company's broader portfolio of rare earth metallization technologies.

The takeaway

REalloys' breakthrough in eliminating hydrofluoric acid from rare earth processing could enable safer, more scalable, and environmentally friendly rare earth metal production in the United States, reducing reliance on China's dominance in this critical supply chain and supporting domestic defense and clean energy industries.