Most people have never heard of a mineral called fluorspar, but they’ve most definitely benefited from it. We all have, in fact, as some of the electronic devices so ubiquitous in our daily lives would not exist in their current forms without it.
Fluorspar is an important commercial source for a chemical element called fluorine, the lightest of the halogens and thus in a league of its own for a variety of industrial applications. Fluorspar is also found in things such as cement and steel, not to mention camera lenses and other optical products. It is classified as a critical mineral in the United States.
James Walker understands that part of his role as Chief Executive Officer of Ares Strategic Mining (CSE:ARS) is to educate the public about the case for fluorspar, especially as Ares is currently the only U.S.-based fluorspar company with a permitted mine.
“It’s no surprise if you haven’t heard of fluorspar – honestly, most people haven’t,” Walker says candidly during a mid-November interview with Canadian Securities Exchange Magazine.
The U.S. once had a thriving fluorspar sector, but this was years ago before China grew its presence and flooded the market with cheap product. As a result, the U.S. fluorspar industry has been virtually nonexistent for decades.
That could change if Ares is successful in producing fluorspar from its Lost Sheep Mine in Utah.
The company went on a search some years ago for projects that it could bring into production quickly, required modest capital spending and contained something for which there was clear customer demand. Fluorspar wasn’t on Walker’s radar at first, but one day his team came across artisanal miners in Utah who were digging it out of the ground, bagging it and selling it directly to steel mills. Walker was intrigued, to say the least.
Lost Sheep was a lucky find, according to the CEO. “One of the geologists I was working with at the time had experience with fluorspar, having worked on Europe’s largest fluorspar mine. When he brought it to my attention, my first reaction was the same as most people’s: What’s fluorspar? But from there, everything started to fall into place.”
With a relatively low capital outlay, Ares seized the chance to build a modern, efficient industrial process to produce significant amounts of fluorspar domestically. The team viewed Lost Sheep as an opportunity to revive the U.S. fluorspar industry and claim significant market share. “With this fluorspar project, the material coming out of the ground was already about 50% of the final product, so the processing required was minimal,” Walker explains.
Ares inherited Lost Sheep’s permits with the purchase of the mine. Even more compelling was that the Lost Sheep Mine was part of a much larger fluorspar anomaly, stretching around 16 kilometres along an area in Utah called Spor Mountain. Fluorspar was everywhere, with showings breaking through to the surface and pipes in multiple locations. “It was fascinating,” says Walker.
Lost Sheep had never been professionally developed so Ares started by conducting geophysics, including LiDAR and electromagnetic surveys, to pinpoint where the anomalies were. From there, the Ares team began drilling, collected samples and conducted metallurgical testing.
Ares also engaged international partners to design the infrastructure for processing the fluorspar. With their help, the company designed plant layouts and, thanks to fluorspar’s critical mineral status, secured federal support in the form of a United States Department of Agriculture loan. This enabled Ares to purchase a 50-acre industrial site with existing infrastructure, including buildings that could be used for a processing plant.
A three-storey lumps plant is already on site, and Ares is now working to construct a flotation plant with support from the state of Utah. The facility is designed to produce higher-grade fluorspar for chemical manufacturers and defence contractors. There is critical infrastructure, including a rail spur for efficient transportation of the fluorspar, heavy mining equipment and an advanced ramp system to access the ore bodies.
Geologically, Lost Sheep is a pipe system that consists of non-contiguous pipes clustered together. This structure allows Ares to install a ramp system – a corkscrew-like framework – that intersects multiple ore bodies. Based on this setup, Ares reports that it should be able to extract around 130,000 tons to 140,000 tons of earth annually, which could translate into around 50,000 tons of final product per year for sale.
“When we first ran our estimates, we based them on a high-grade flotation product priced at about $500 per ton, which would result in roughly US$30 million in annual revenue,” Walker says. “However, given the upward trend in fluorspar prices, those numbers could be higher.”
Another advantage is relatively low operating expenses. Unlike many mining operations, Lost Sheep doesn’t require a large workforce.
Ares has agreements lined up with end users of fluorspar and has been forging partnerships with entities such as the Department of Defense and the Department of Energy, which are actively seeking domestic supply sources.
For example, the U.S. produces around 80 million tons of steel annually, requiring about 20 pounds of fluorspar per ton. And with aluminum production using about 60 pounds of fluorspar per ton, these two industries alone create a significant domestic requirement.
That growing demand isn’t limited to traditional industries like steel and aluminum, however. The rise of lithium-ion batteries is set to become a major driver of fluorspar consumption, reshaping the market’s dynamics.
And this brings us to acid-grade fluorspar, or acid spar, which undergoes additional chemical refining to achieve a purity level of 97% calcium fluoride (CaF2). Currently, there is no operation in the U.S. producing acid spar, marking a substantial opportunity for producers.
“If we have our plant up and running, we’ll be able to serve about two-thirds of the U.S. fluorspar market,” Walker explains. “By producing acid spar, we can cater to a much larger portion of the U.S. fluorspar market and meet the needs of these key industries.”
International demand for fluorspar is increasing too, as China’s fluorspar reserve has suffered due to excessive mining. The Chinese government tightened its control over the material, leading to a decline in fluorspar exports. Official customs data reveals a steady drop in China’s fluorspar exports over the years, accompanied by a surge in imports, particularly in 2023. Now that China is facing these challenges, the pressure they once placed on the market is gone. This creates an opportunity for other countries to step in.
These factors mean it is a good time to be transitioning from exploration to production. But shifting from a junior mining company to a manufacturing company brings challenges from both operational and financial standpoints.
Walker is counting on his experience in nuclear engineering and project management to lead the company into its next phase. In the past, the Ares CEO has helped to build large manufacturing facilities such as for reactor cores for submarines – billion-dollar projects that required hundreds of personnel.
“I have had extensive exposure to large-scale project management, cost control and the implementation of manufacturing and processing operations, which has been invaluable in how I approach managing new manufacturing operations at Ares, overseeing processing and organizing the team,” Walker says.
Fluorspar demand is expected to grow by 2.76% annually over the next five years, according to Mordor Intelligence. Given this outlook, Walker sees a lot of potential. In five years, the CEO is looking beyond the Utah operation toward untapped potential across the entire continent.
“There used to be a thriving fluorspar industry in the U.S. before it moved overseas, and effectively, we’re working to bring it back.”
This story was featured in Canadian Securities Exchange Magazine.
Learn more about Ares Strategic Mining at https://www.aresmining.com/.