HyProMag USA’s flagship rare earth magnet recycling and manufacturing hub in Texas is making strong progress, with EPCM Detailed Design now 25% complete.
The design incorporates advanced grain boundary diffusion (GBD) techniques, allowing the production of magnets with coercivity exceeding 20 kOe—a key milestone in high-performance permanent magnet manufacturing.
In parallel, the HyProMag Group has expanded operations at its UK pilot facility, tripling throughput capacity and completing more than 50 Hydrogen Processing of Magnet Scrap (HPMS) runs in the past six months. This has resulted in the production of approximately 900 kilograms of recycled NdFeB alloy powder at the Tyseley Energy Park site.
Looking ahead to the U.S. expansion, HyProMag has shortlisted four potential hub locations in the Dallas–Fort Worth area, each ranging from 125,000 to 140,000 sq. ft. The company expects to begin baseline permitting in Q3 2025.
Once operational, the Texas Hub is projected to deliver an annual output of 750 metric tons of recycled sintered NdFeB magnets along with 807 metric tons of associated NdFeB co-products—positioning HyProMag as a key supplier in the U.S. rare earth magnet supply chain.
Julian Treger, CoTec CEO commented: “We are very pleased with the progress of the EPCM Detailed Design. The learnings from HyProMag’s facilities in the UK and Germany continue to inform PegasusTSI’s and BBA’s work and support an accelerated project schedule targeting first magnets in H1 2027. In parallel with the EPCM Detailed Design, the company is focused on securing funding from the U.S. Government, commercial lenders, equity providers and off takers. With the commencement of the long-loop Concept Study, the Company is in a unique position as it provides both short and long-loop rare earth permanent magnet recycling. HyProMag USA’s proposed U.S. facility fully meets the requirements of the U.S. Defence Production Act (“DPA”) Title III and will provide a secure, long-term, commercial-scale magnet recycling and production facilities in the United States.”
Will Dawes, Mkango CEO commented: “HyProMag USA is very well positioned to provide a new domestic sustainable source of rare earth magnets for the United States, and it is fantastic to see the project progress towards near term development at pace. This creates a strong platform for further expansion, complementing the ongoing HyProMag developments in the UK and Germany.”
The Feasibility Study includes the Texas Hub and two pre-processing facilities located in South Carolina and Nevada respectively. In March 2025, HyProMag USA announced the expansion of the detailed engineering phase to include three HPMS vessels[v] and that it was initiating concept studies for further expansion and complementary “long- loop” recycling[vi]. The Texas Hub’s annual production is expected to be 750 metric tons per annum of recycled sintered NdFeB magnets and 807 metric tons per annum of associated NdFeB co-products (total payable capacity – 1,557 metric tons NdFeB within five years of commissioning) over a 40-year operating life. It is expected the production facility will provide significant optionality to supply the U.S. market with additional NdFeB alloy powder while assisting in revitalising the U.S. magnet sector with the creation of 90-100 skilled magnet manufacturing jobs.
For further information on Mkango, please contact:
Mkango Resources Limited
Alexander Lemon William Dawes
President Chief Executive Officer
UK: +44 20 7372 2744
