Iondrive Limited announced an updated technical and economic evaluation for a single United States IONSolvâ„¢ rare earth recycling module processing end-of-life permanent magnets, with the study indicating a post-tax NPV at a 10% real discount rate of US$243 million, pre-tax NPV of US$348 million, annual EBITDA of US$62.1 million on revenue of US$121.8 million, and development capital of US$11.9 million over a ten-year operating life following one construction year; the model assumes throughput of 2,402 tpa, feedstock grade of 30.66% REO, production of about 630 tpa rare earth oxide product including about 624 tpa payable Nd, Pr and Dy oxides, and realised pricing at 90% of North American benchmark assessments, while applying overall modelled recoveries of 89.3% for Nd, 88.5% for Pr and 88.8% for Dy, which are below independently validated single-pass leach results and still require integrated testwork to confirm full flowsheet recovery to final product; the upgrade from the November 2025 evaluation is driven mainly by richer assumed feedstock and higher dysprosium content rather than process changes, with dysprosium contributing nearly half of base-case revenue, and the company stresses that feedstock grade, composition, availability, pricing, utilisation, permitting, funding, site selection and offtake remain key uncertainties, meaning the study supports a planned first commercial module in Oklahoma but does not constitute a final investment decision.
Key Points
The updated evaluation for one US IONSolvâ„¢ module returns a post-tax NPV of US$243 million and a pre-tax NPV of US$348 million.
The modelled operation generates annual revenue of US$121.8 million and annual EBITDA of US$62.1 million, with a 51.0% EBITDA margin.
Development capital is estimated at US$11.9 million, with sustaining capital of US$6.0 million over the ten-year operating life.
The study assumes feedstock throughput of 2,402 tpa at an assumed REO head grade of 30.66%, producing about 630 tpa of rare earth oxide product.
Approximately 624 tpa of payable product is modelled as neodymium, praseodymium and dysprosium oxides.
The economic model uses assumed overall recoveries of 89.3% for Nd, 88.5% for Pr and 88.8% for Dy, below independently validated single-pass leach recoveries.
Overall recovery through to final mixed rare earth oxide product has not yet been validated through integrated flowsheet testwork.
The revised economics are driven mainly by richer assumed feedstock and higher dysprosium content compared with the November 2025 evaluation.
Dysprosium represents about 4.7% of modelled production by mass but about 49.5% of base-case revenue, making its assumed content and price highly material.
Base-case realised product value is US$193/kg, based on 90% realisation of management-adopted North American benchmark prices.
Feedstock cost is modelled at US$30.4 million per year, or US$48.30/kg of product, representing 51% of total operating cost.
Sensitivity analysis shows no tested pricing case produces a negative NPV, with project value most sensitive to realised product prices and operating costs.
The model is ungeared, expressed in real US dollars, uses a 10% real discount rate and 30% corporate tax rate, and assumes no production ramp and no working capital.
Iondrive says the evaluation supports the planned first commercial module in Oklahoma, but it is a study only and not a final investment decision.
Next steps include front-end engineering design, US feedstock qualification, site selection, permitting, and progressing supply, offtake and funding arrangements.
IMPORTANT NOTE: This information is autogenerated and has not been reviewed for accuracy or completeness. You should refer to the full announcement here for further information.