STRP

This proposal aims to advance, validate and optimize High Pressure Slurry Ablation (HPSA) developed by DISA Technologies Inc. for the liberation of rare earth elements (REEs) and critical minerals (CMs) from different geological resources. HPSA employs high-velocity, opposing slurry jets that induce particle-on-particle collisions, selectively disaggregating mineral grains based on hardness contrasts and bonding strength. Compared with conventional grinding, HPSA enables selective liberation at coarser particle sizes, reducing overgrinding, reagent consumption, and energy use. A prior case study by DISA demonstrated that HPSA increased total REE recovery from 29% to more than 95% while reducing downstream processing volume by over 40%. Building on this foundation, the proposed research will evaluate and optimize key process parameters, including slurry concentration, nozzle velocity, residence time, specific energy input, collision frequency and particle size distribution using a HPSA system to be installed at the University of Wyoming. Comprehensive characterization analyses will be conducted to quantify recovery improvements. Using Response Surface Methodology (RSM) and statistical modeling, the project will define a validated performance envelope and develop a predictive scale-up model applicable to multiple REE ore types. Accomplishing these milestones will elevate current Technology Readiness Level (TRL) 6 to TRL 7–8. Combining academic research capacity, industrial fabrication expertise and commercialization experience, the collaboration between UW and DISA will deliver an integrated HPSA pilot system with an incorporated commercial design that is capable of transforming mineral processing efficiency, supporting the U.S. CM supply chain, and strengthening Wyoming’s position in resource innovation.