Aluminum alloys containing scandium offer high-strength, corrosion-resistant, weldable alternatives to existing aluminum options and deliver significant property improvements and light-weighting opportunities, particularly in transportation applications. Military and strategic applications are expected to be significant as well.
In order to serve this demand, NioCorp Developments Ltd. plans to produce an aluminum-scandium master alloy (Al-Sc MA) product from mining and upgrade facilities to be located in the U.S. This investment is subject to receipt of project financing and consummation of mining operations at the Elk Creek Project, which could enable commercial and defense manufacturers to replace select existing aluminum parts in vehicles.
Scandium is one of several strategic metal products that NioCorp plans to make from its Elk Creek Critical Minerals Project in Nebraska. Once in commercial operation, the scandium component from this mine could potentially position NioCorp as one of the largest producers of Al-Sc MA in the world. Still, more scandium production would need to come online in both North America and Europe, if more than a small handful of manufacturers are to benefit from these high-performance aluminum alloy variants.
“Our planned scandium oxide and master alloy production could be large enough to enable manufacturers to supply aluminum-scandium alloy parts to electric and/or conventional vehicles,” said Mark Smith CEO and executive chairman of NioCorp. “As recent forecasts from Morningstar and others predict, EV and hybrid sales are expected to grow into the tens of millions per year over the next decade and longer. This is one of the reasons the U.S. Government designated scandium as a critical mineral for the U.S. economy and national security and underscores the importance of getting multiple new, reliable sources of scandium supply for North America online as rapidly as possible.” According to the Morningstar forecast, EV and hybrid vehicle sales combined are estimated to hit approximately 60 million units by 2030.
Smith added, “Beyond the growth forecast for electric and hybrid vehicle sales, we anticipate additional demand coming from the defense sector, given scandium’s ability to lightweight, strengthen, and improve corrosion resistance to land, air, space, and sea-based systems.”
During a recent investor conference, Smith discussed these trends. He also presented information on the company’s phased approach to commercial-scale Al-Sc master alloy production in the U.S. He noted that the traditional method of introducing scandium into Al-Sc alloys is via a master alloy containing 98% aluminum and 2% scandium. However, NioCorp is now engaged in pilot-scale production of Al-Sc MA, containing up to 5% or more scandium by weight, and the company anticipates producing the pilot-scale ingots of its Al-Sc MA over the coming weeks.
After the company obtains sufficient project financing, completes both pilot-scale and commercial demonstration testing operations, and validates the technical and economic feasibility of proceeding to full-scale commercial master alloy production, NioCorp plans to construct and operate a commercial-scale master alloy facility, which will operate in parallel with its planned Elk Creek Project. If it achieves all of these steps, the Elk Creek Project plans to produce more than 100 tonnes of scandium oxide annually, with some or all of the oxide product to be further processed by NioCorp into an Al-Sc MA for direct sale to aluminum alloy producers and customers.
“Our pilot-scale demonstration plant has produced scandium metal and is expected to produce test aluminum-scandium master alloy ingots, with a goal of producing 1-kilogram ingots at pilot scale, “said Smith. “Our next step is to produce master alloy at the Commercial Demonstration level, scaling from 10 kg ingots to 100 kg ingots. Finally, once we secure sufficient financing to move to construction and eventual commercial operation, among other matters, we intend to move to full-scale production of master alloy.”