How Waterless Mineral Processing Is Transforming American Resource Independence
Washington, Tuesday, 27 October 2026.
A new Texas-based partnership eliminates water dependence in critical mineral refining, offering domestic producers a lower-cost path to secure vital materials for clean energy and defense manufacturing.
Strategic Partnership Launches Waterless Processing in Texas
ElementUSA Inc. and DryFlow Magnetics officially announced their strategic collaboration on October 27, 2026, to deploy waterless mineral processing technology at ElementUSA’s Critical Resource Accelerator (CRA) facility in Cedar Park, Texas [1]. The partnership marks a significant step toward reducing the United States’ reliance on water-intensive mineral refining methods, which have long posed environmental and operational challenges. DryFlow’s patented dry magnetic separation technology, validated in South Australia with support from CSIRO and the Government of South Australia, is designed to process feedstock with moisture levels above 10%, upgrading low-grade magnetite (under 30% iron content) to high-purity concentrates exceeding 67% iron [1][3]. The deployment at Cedar Park will include a test unit to allow North American project owners to evaluate the technology’s performance before scaling up commercial applications [1].
Operational and Environmental Advantages Drive Adoption
The waterless processing method developed by DryFlow Magnetics eliminates the need for traditional water-based separation techniques, which are both resource-intensive and environmentally taxing [3]. According to DryFlow’s CEO, Brett Boynton, the technology offers a pathway to unlock previously inaccessible iron ore resources by reducing water and energy consumption compared to conventional methods [3]. The company’s upcoming commercial demonstration plant in South Australia, supported by a A$48.4 million grant from the Australian Renewable Energy Agency (ARENA), will operate at a capacity of 1.5 million metric tons per year, producing high-purity iron concentrate suitable for low-emissions steelmaking [3]. This initiative aligns with global efforts to transition toward sustainable industrial practices while maintaining economic viability [3].
Expansion Plans and Industry Impact
DryFlow Magnetics, an Australian industrial technology company founded in 2024, has positioned itself as a key player in the dry processing sector, backed by CSIRO, the South Australian Government, and venture firms such as Orion Industrial Ventures and Virescent Ventures [2]. The company’s expansion into the U.S. market, anchored in Texas, is expected to accelerate the adoption of waterless mineral processing across North America [1]. ElementUSA’s CRA facility in Cedar Park will serve as a testing hub, enabling project owners to assess DryFlow’s technology before committing to full-scale deployment [1]. Chris Young, ElementUSA’s Chief Strategy Officer, emphasized the importance of pairing processing expertise with innovative technologies to build scalable solutions for overlooked resources [1].
Future Implications for Critical Minerals and Clean Technology Sectors
The collaboration between ElementUSA and DryFlow Magnetics arrives at a critical juncture for the U.S., where demand for critical minerals is surging due to the expansion of clean energy technologies and defense manufacturing [GPT]. By eliminating water dependency in mineral refining, the partnership offers a scalable solution to bolster domestic production, reduce industrial utility costs, and meet stringent environmental standards [1]. DryFlow’s technology, which has demonstrated the ability to achieve high-purity iron concentrates without water, could redefine the economics of mineral processing and support the transition toward low-emissions industrial supply chains [3]. As the U.S. seeks to strengthen its resource independence, the Cedar Park test unit and DryFlow’s upcoming commercial plant in Australia could serve as blueprints for future deployments worldwide.