US-based independent, nonprofit applied science and technology organisation Battelle has demonstrated a promising biotechnology-based solution for rare earths processing.

The organisation is undertaking research to address one of the US's most pressing supply chain challenges - rare earths processing - as demand for critical minerals accelerates.

In research published in Chemical Science, Battelle researchers and collaborators demonstrated that engineered calcium-binding proteins can selectively separate rare earth elements with high purity and yield.

The work offers a potential alternative to conventional rare earth processing methods and represents a breakthrough in applying biology to critical mineral recovery.

The research achieved single-stage, chelator-free separation of lanthanum and neodymium with more than 90% purity and yield while removing non-rare-earth ions from simulated leachate streams and industrial feedstock materials.

The advancement comes as policymakers, manufacturers and technology companies increasingly are focusing on strengthening domestic supply chains for critical minerals that underpin clean energy systems, advanced manufacturing, consumer electronics and national security technologies.

"America's critical minerals challenge is often viewed through the lens of engineering chemistries, but biology may offer an important new part of the separations and recovery solution. Our research demonstrates how engineered proteins can selectively recognize and separate rare-earth elements (REEs) with remarkable precision.

"By leveraging biological mechanisms, we have the opportunity to create more efficient and potentially more sustainable approaches to recover these vital resources," says Battelle operational biotechnologies research leader Dr Kate Kucharzyk.

REEs are essential for manufacturing permanent magnets used in electric vehicles and wind turbines, as well as components found in smartphones, advanced electronics, defence systems and emerging AI infrastructure.

While demand continues to rise, the separation and purification of REEs remains one of the most complex and costly steps in the supply chain.

Battelle's approach draws inspiration from nature. The team engineered calcium-binding peptides that can selectively interact with specific REEs, creating a highly targeted separation process capable of distinguishing between chemically similar materials that traditionally require multiple processing steps.

The work highlights a growing convergence of biotechnology, materials science and advanced manufacturing, areas increasingly viewed as critical to US competitiveness in strategic technology sectors.

The research was supported by the Defense Advanced Research Projects Agency's Environmental Microbes as a Bioengineering Resource programme.

Battelle researchers believe the protein-based approach demonstrates significant promise for future scale-up and commercialisation efforts, potentially enabling more environment-friendly and efficient rare earth separation technologies.

As global competition for critical minerals intensifies, Battelle continues to explore transformative solutions at the intersection of biology, chemistry and engineering.

"Critical minerals are essential to the future of energy, computing and national security. By bringing biotechnology into the conversation, we're expanding the range of solutions available to strengthen domestic supply chains and support future innovation," Kucharzyk concludes.