MTM Critical Metals (ASX: MTM) has ticked off a major milestone on its journey to revolutionising critical metals processing, completing the engineering design phase for its 1-tonne-per-day (1TPD) Flash Joule Heating (FJH) demonstration plant. The achievement puts the company firmly on track to begin operations by late 2025, marking a key step toward proving the commercial viability of its innovative metal recovery technology.
The demonstration plant, designed to extract valuable metals such as gallium, germanium, and rare earth elements (REEs) with improved efficiency and environmental outcomes, is seen as a potential game-changer for the industry.
Engineering Blueprint Finalised
The completion of the process design phase provides MTM with a detailed operational roadmap for the FJH demonstration plant. The blueprint defines essential process parameters such as material balances, flow rates, and operating conditions, ensuring the technology can be deployed at scale.
Conceptual artist’s impression of the Core Process Area of the FJH-1000 Demonstration Plant
Key elements of the completed process design include:
✅ Feedstock Handling: Efficient preparation and introduction of mineral concentrates and metal-bearing waste.
✅ Proprietary Reactor Design: Fine-tuning reaction kinetics and energy input to maximise impurity removal.
✅ Gas Management: Ensuring emissions control and capturing valuable byproducts.
✅ Metal Recovery & Refining: Extracting high-purity metal chlorides or oxides, ready for further processing.
✅ Process Control & Automation: Implementing real-time monitoring to optimise performance and efficiency.
With this milestone achieved, MTM has now moved into the procurement phase, securing long-lead equipment such as gas clean-up systems to meet the end-of-year 2025 operational target.
“We now have a clear technical roadmap for the 1TPD plant,” said MTM Managing Director and CEO Michael Walshe. “With procurement, permitting, and site selection advancing as planned, we remain firmly on track to begin operations by the end of 2025.”
Why Flash Joule Heating (FJH) Matters
MTM’s FJH technology is an advanced electrothermal process that rapidly heats metal-bearing materials, allowing for selective extraction of valuable elements. Compared to traditional metal recovery methods, the technology offers several advantages:
🔹 Higher Efficiency: FJH optimises reaction conditions to maximise metal recovery rates while minimising waste.
🔹 Lower Energy Consumption: The process requires significantly less energy than conventional smelting or leaching methods.
🔹 Improved Sustainability: By reducing reagent use and emissions, the process aligns with global efforts to make critical metals extraction greener.
The demonstration plant will validate FJH’s ability to recover metals from various feedstocks, including mine tailings and e-waste. If successful, MTM plans to roll out larger modular processing units, potentially disrupting the way critical metals are sourced and supplied worldwide.
Strategic Site Selection in the U.S.
As part of its commercialisation roadmap, MTM is prioritising site selection efforts in Texas and Louisiana, known for their industrial infrastructure, pro-business policies, and streamlined permitting processes. The company is actively engaging with technology parks and economic development agencies to secure a pre-permitted site—an approach that could significantly reduce approval timelines.
According to MTM, securing a site in these states would allow it to tap into established industrial supply chains and a skilled workforce, accelerating deployment and scaling.
“Our focus on the U.S. isn’t just about commercialisation—it’s about reshoring critical metals production and strengthening America’s supply chain security,” Walshe noted. “By developing this technology in the U.S., we are positioning MTM as a leader in sustainable critical metals processing.”
A final site selection decision is expected by Q2 2025.
KnightHawk Engineering Doubles Down on MTM’s Success
One of the most telling signs of confidence in the project is the growing commitment from KnightHawk Engineering (KHE), MTM’s key design partner. KHE has not only completed the FJH process design but has also aligned its commercial terms with project milestones.
In a strong vote of confidence, KHE has agreed to convert a portion of its deferred success fees into equity in MTM. The agreement, based on MTM’s share price at the end of 2024 (A$0.275 per share), will see KHE receive 345,012 MTM shares.
KnightHawk CEO and Chief Engineer Cliff Knight called the FJH process a “truly disruptive innovation” and said his firm was proud to be part of scaling the technology for commercial deployment.
MTM Non-Executive Chairman John Hannaford echoed this sentiment, stating: “KHE’s decision to convert fees into equity is a testament to their belief in our technology and the long-term potential of this project. Their continued support is invaluable as we move closer to full-scale deployment.”
In addition to financial backing, KHE has also provided dedicated office space for MTM executives at its Houston facility, further strengthening the collaboration.
Next Steps on the Road to Commercialisation
With the process design phase behind it, MTM is now focused on executing its commercialisation roadmap:
- Q2 2025: Final site selection in Texas or Louisiana.
- Mid-2025: Completion of long-lead equipment procurement.
- Q4 2025: Commissioning and first feedstock processing.
- Beyond 2025: Scaling up to larger modular production units.
The 1TPD demonstration plant will serve as a critical proving ground, generating the operational data needed to refine the process and secure offtake agreements with industrial partners.
Final Thoughts
MTM Critical Metals is methodically ticking the right boxes on its path to commercialisation. The completion of the process design phase de-risks the project significantly, providing a clear framework for deployment. Meanwhile, the commitment from KnightHawk Engineering and the strategic site selection process reinforce confidence in the company’s ability to deliver.
With first production targeted for late 2025, investors will be watching closely to see if MTM can successfully execute its next phase—and whether FJH technology can truly disrupt the critical metals industry. If all goes to plan, this could mark the beginning of a new era in sustainable metal recovery.
