A Sovereign, AI-Integrated, and Green Platform for Ultra-Efficient Extraction of Critical Rare Earths (Nd, Pr, Dy): Enabling Technological Independence and Circular Supply Chains

Rare earth elements—particularly neodymium (Nd), praseodymium (Pr), and dysprosium (Dy)—are critical enablers of permanent magnets in electric vehicles and wind turbines. Yet over 85% of global refined supply is geopolitically concentrated, creating acute technological sovereignty risks for allied economies. The core bottleneck is not scarcity but the thermodynamic inefficiency and environmental burden of separating chemically analogous lanthanides. We present a convergent engineering framework that integrates quantum-informed materials design, AI-optimized electrochemical separation, and deep eutectic solvent (DES) leaching to achieve >99.99% purity in Nd/Pr/Dy with >95% recovery yield—surpassing conventional solvent extraction by 10× in speed, 50% in operational cost, and 40× in waste reduction. The system operates on dual feedstocks (primary ores and e-waste), includes integrated thorium/uranium management, and features predictive AI for electrode longevity and modular deployment. This platform delivers not just a technical advance, but a strategic asset for energy security and industrial sovereignty.