Method for Producing Rare Earth Metals via Thermite Reduction of Rare Earth Compounds with Aluminum

原文（中文）

A method and cascade reactor system for producing elemental rare earth metals and rare earth-aluminum alloys via aluminothermic reduction are disclosed. The method involves combining rare earth oxides or halide salts with aluminum powder, initiating a thermite-type reaction under inert or controlled atmospheric conditions, and recovering the molten metal product. Fluxing agents may be used to enhance slag fluidity and phase separation. The cascade reactor comprises multiple thermite zones with staged ignition, thermal transfer mechanisms, and slag separation interfaces, enabling sequential reduction of mixed feedstocks. The system supports both batch and continuous formats and achieves high recovery yields, reduced aluminum contamination, and compatibility with alloying and post-purification processes. The invention is adaptable to individual rare earth species and mixed oxide concentrates, offering a scalable, energy-efficient, and environmentally favorable route to rare earth metal and alloy production.