Aclara Inaugurates Pilot Plant for Heavy Rare Earths in Brazil

Aclara 

New facility uses patented clean-tech process to produce dysprosium and terbium from Carina project clays

Aclara Resources has launched its semi-industrial heavy rare earths pilot plant in Aparecida de Goiania, in Brazil's Goias state. The pilot facility is a milestone for Aclara’s Carina project, aiming to process 200 tonnes of ionic clays and produce around 150 kilograms of heavy rare earth carbonates, including dysprosium and terbium—key elements in electric vehicle and wind turbine magnets.

Clean Technology and Closed-Loop Design

At the heart of the pilot is Aclara’s circular mineral harvesting technology, which eliminates the need for blasting, milling, or tailings dams. The closed-loop system recycles over 95% of water, ensures zero liquid discharge, and recovers 99% of reagents, aligning with sustainability and cost-efficiency goals.

The design builds on trials previously conducted in Chile, with 25t of Carina clays already tested. The new facility will support pre-feasibility and feasibility studies led by Hatch, and provide high-purity samples for US-based separation facilities and offtake agreements.

A Step Toward Global Energy Transition

Aclara CEO Ramón Barúa emphasized the importance of stakeholder support, particularly from Nova Roma and Brazilian authorities, in enabling the Carina project. He projected that the future full-scale plant could support magnet production for five million EVs per year.

Brazil’s Vice-Governor of Goiás, Daniel Vilela, praised the $500 million (R$2.8bn) investment for its potential to generate thousands of jobs and elevate the state’s status in the global rare earth supply chain.

Two patents protect Aclara’s process, already granted in Brazil, Chile, the US, and China.