HyProMag USA increases Texas Hub capacity to 1,526 metric tons
HyProMag USA has increased the projected magnet production capacity at its Texas Hub to 1,526 metric tons annually, with a post-tax NPV of US$416 million. The company has started procuring long-lead equipment and is targeting H2 2027 commissioning. Discussions for feedstock, offtake, and financing are advancing alongside plans for future expansion.

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HyProMag USA, a joint venture between Mkango Resources Ltd and CoTec Holdings Corp, has increased the projected magnet production capacity at its Texas Hub to 1,526 metric tons annually. The updated project economics indicate a post-tax Net Present Value (NPV) of approximately US$416 million based on current market prices, with a real internal rate of return (IRR) of 26.3%. The company has commenced procurement of long-lead equipment and is targeting commissioning in the second half of 2027.
Following the completion of a Class 2 AACE capital cost estimate in Q4 2025, HyProMag USA has begun ordering critical-path equipment, including three Hydrogen Processing of Magnet Scrap (HPMS) vessels. Detailed engineering is advancing, and the company is engaging with feedstock suppliers and potential offtake partners. The total initial capital cost is estimated at approximately US$152 million, including an 8.2% contingency and detailed design costs, over a one-year construction phase.
Project Economics and Capacity
The detailed engineering for the rare earth magnet recycling and manufacturing operation at the Ironhead facility in Northlake, Texas, supports two pre-processing spoke sites at Intelligent Lifecycle Solution (ILS) facilities in South Carolina and Nevada. The project is designed to have a 40-year operating life.
| Metric | Value |
|---|---|
| Annual NdFeB magnet production | 1,048 metric tons |
| Annual NdFeB co-products | 478 metric tons |
| Total payable NdFeB capacity | 1,526 metric tons |
| Post-tax NPV (current prices) | US$416 million |
| Real IRR (current prices) | 26.3% |
| Post-tax NPV (forecast prices) | US$797 million |
| Real IRR (forecast prices) | 37.1% |
| Total initial capital cost | US$152 million |
Operational Developments
HyProMag USA has initiated formal power supply discussions with Oncor Electric Delivery Company LLC, expecting the facility to be predominantly supplied by renewable resources. Preparatory work is underway at the Ironhead building in the Dallas-Fort Worth metro area. Additionally, three Inserma "3rd generation" hard disk drive (HDD) magnet separation systems have been installed at the ILS pre-processing sites in Williston, South Carolina, and Las Vegas, Nevada.
The company is diversifying its feedstock base through its partnership with ILS, targeting bulk NdFeB feedstock such as electric motor rotors, wind turbine magnets, and end-of-life MRI machines. Offtake discussions are ongoing with multiple potential customers, and magnet samples are being provided for product verification.
Strategic Expansion and Financing
HyProMag USA is targeting the completion of a Class 3 AACE estimate and optimal configuration study in Q3 2026 for additional plants. The objective is to expand U.S.-based production to approximately 4,656 metric tons of NdFeB saleable products. The company is also in discussions with three financial institutions to advance project financing.
Julian Treger, CoTec CEO, stated that ordering long-lead items keeps the Texas Hub on track and signals confidence in the project schedule. Will Dawes, Mkango CEO, highlighted the company's competitive advantages, including energy-efficient HPMS and Inserma technologies, which are already commissioned and operating in the UK and Germany.
How will the outcome of the current project financing discussions impact the timeline for the targeted commissioning in the second half of 2027?
What specific factors could bridge the gap between the current market price NPV of US$416 million and the forecast price NPV of US$797 million?
How will the company secure the necessary volume of bulk feedstock from electric motors and wind turbines to support the planned expansion to 4,656 metric tons?


























