Power Minerals Begins Metallurgical Testing to Unlock Magnet Rare Earths at MDF
Key Takeaways
- Power Minerals has dispatched more than 100kg of drill samples for mineralogical and metallurgical testing at Morro do Ferro, marking the project's transition from pure exploration into development-pathway work.
- Preliminary SEM and EPMA analysis has identified bastnäsite-group minerals at MDF — the same mineral processed at Mountain Pass in the US — opening the door to established, proven processing technologies rather than novel methods.
- The company is targeting selective beneficiation to enrich the four magnet rare earths (NdPrDyTb) while rejecting lower-value cerium-rich material, which would improve concentrate quality and commercial value.
- A metallurgical flowsheet for a rare earth concentrate is targeted by end of 2026, with PQ-diameter drilling and a larger metallurgical test programme to follow in 2027.
- The ongoing drilling programme at MDF continues in parallel, working toward a maiden Mineral Resource Estimate alongside the metallurgical workstream.
Metallurgical studies underway at Morro do Ferro rare earth project
Power Minerals (ASX: PNN) has commenced metallurgical and mineralogical studies at its Morro do Ferro (MDF) rare earth project in Minas Gerais, Brazil, marking a meaningful step forward in the project’s development pathway.
More than 100kg of drill samples have been dispatched for mineralogical assessment and metallurgical testing. The work represents a core parallel workstream alongside the ongoing drilling programme that is working toward defining a maiden Mineral Resource Estimate for the project.
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What the early mineralogy is telling Power Minerals
Preliminary examinations using scanning electron microscopy (SEM), field-emission SEM, and electron probe microanalysis (EPMA) have identified bastnäsite-group minerals and a separate cerium-bearing phase, cerianite, at MDF. These observations are broadly consistent with limited historical work on near-surface material, which also reported minor rare earth phosphate minerals.
The mineralogical work builds on a drilling campaign that returned record MREO grades at Morro do Ferro, with results placing the project among the higher-grade magnet rare earth discoveries on the ASX.
Rare earth mineralisation occurs within soft, clay-rich material associated with magnetite. Further work is ongoing to establish individual mineral species, relative abundances, and variability between drill holes and at depth.
Critically, this mineralogical distribution creates an opportunity to investigate preferential recovery of higher-value rare earths while rejecting cerium-rich material and gangue (the valueless rock and minerals surrounding the ore). The four critical rare earth elements (REE) being targeted for enrichment are:
- Neodymium (Nd)
- Praseodymium (Pr)
- Dysprosium (Dy)
- Terbium (Tb)
These four elements, sometimes referred to collectively as NdPrDyTb or magnet rare earths, are central to permanent magnets used in electric vehicles and wind turbines.
Why bastnäsite mineralisation matters for processing
Bastnäsite is a rare earth carbonate fluoride mineral and one of the most commercially significant rare earth-bearing minerals in the world. It has a long track record of industrial-scale processing, including at the Mountain Pass Rare Earth Project in the United States, where the flowsheet incorporates flotation and leaching.
For investors, the identification of bastnäsite-group minerals at MDF matters for one practical reason: Power Minerals can draw on established, proven processing technologies rather than developing novel methods from scratch. That reduces technical risk and could accelerate flowsheet development.
The company’s stated approach is to assess the applicability of conventional equipment and reagents to MDF’s specific mineralogy, covering mineral liberation, rare earth recovery, reagent requirements, and impurity management.
The goal of selective beneficiation is to produce a concentrate enriched in the four magnet rare earths, both in grade and as a proportion of total rare earth oxides (TREO), by rejecting lower-value cerium-rich material. This improves downstream concentrate quality and commercial value, though the company notes achievable enrichment and recoveries remain subject to mineralogical confirmation and metallurgical testing.
The magnet rare earth profile at MDF has been a central focus of project characterisation work, with NdPrDyTb grades and their proportion of TREO both assessed as part of the case for selective beneficiation.
Alistair Stephens, CEO, Power Minerals
“Commencing this program is an important step in establishing the processing potential of Morro do Ferro. Our initial mineralogical observations provide a foundation to investigate the selective recovery of higher-value rare earths and opportunities to reject cerium-rich material and gangue.
“We are drawing on established rare earth processing technologies, with test work directed at understanding their suitability for Morro do Ferro’s mineralogy. Our priority is to establish a sound technical basis for flowsheet selection, including recovery, concentrate quality and impurity management…”
Programme milestones and what comes next
The near-term target is to develop a metallurgical flowsheet for a rare earth concentrate by the end of 2026. Following the current studies, PQ-diameter drilling is planned at MDF to obtain additional samples for a larger metallurgical test programme in 2027. The company’s core handling facility near MDF in the Poços de Caldas district will support initial sample assessment and associated test work activities.
In parallel, the ongoing drilling programme at MDF continues to work toward defining a maiden Mineral Resource Estimate.
Key programme milestones in sequence:
- Mineralogical studies underway — mineral composition, associations, and variability being established (now)
- Metallurgical flowsheet for rare earth concentrate targeted — end of 2026
- PQ-diameter drilling programme — to follow current studies
- Larger metallurgical test programme — planned for 2027
- Maiden Mineral Resource Estimate — ongoing drilling programme working toward this
| Workstream | Status | Key Objective | Timeline |
|---|---|---|---|
| Mineralogical studies | Underway | Establish mineral species, abundances, and variability between drill holes and at depth | Current |
| Metallurgical flowsheet development | In progress | Develop flowsheet for rare earth concentrate; assess selective beneficiation of magnet REE | End of 2026 |
| PQ-diameter drilling | Planned | Obtain additional samples for larger metallurgical test programme | Following current studies |
| Larger metallurgical test programme | Planned | Expanded testing to refine flowsheet and recovery parameters | 2027 |
| Maiden MRE drilling | Ongoing | Define maiden Mineral Resource Estimate for MDF | Ongoing |
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The investment case for Power Minerals at MDF
MDF sits in Minas Gerais, Brazil, an active critical minerals region, and targets magnet rare earths that sit at the core of clean energy and defence supply chains globally. The commencement of metallurgical studies marks a transition from pure exploration activity toward development-pathway work, which is an important de-risking step for the project.
Power Minerals’ portfolio extends beyond MDF. The company also holds the Salta Lithium Project in Argentina, positioning it across two high-demand critical mineral categories. The company’s stated objective is establishing commercially viable sources of critical minerals for global supply chains, with MDF and Salta representing the two lead assets in that strategy.
Ready to Explore the Metallurgical Potential of Morro do Ferro?
Power Minerals (ASX: PNN) is advancing its high-grade magnet rare earth project in Brazil, with metallurgical and mineralogical studies now underway and a flowsheet for a rare earth concentrate targeted by end of 2026. The identification of bastnäsite-group minerals opens the door to established processing technologies, reducing technical risk as the project moves along its development pathway.
For a closer look at the project’s rare earth grades, selective beneficiation strategy, and upcoming milestones, explore the full Power Minerals investment profile on Discovery Alert.