Wedoany.com Report-May 2, Xerion Advanced Battery has initiated pilot-scale production at its facility in Dayton, Ohio, USA, utilizing its proprietary DirectPlate Molten Salt Electrolysis (MSE) technology for cobalt refinement. This innovative process streamlines the production of high-purity cobalt metal, marking a significant step toward enhancing domestic battery material supply chains.

Xerion’s lab tests yielded more than 98% recovery and more than 99% pure cobalt metal, producing more than 100kg.

The DirectPlate MSE technology, originally developed for battery component synthesis, offers a single-step, continuous process that reduces the complexity and cost of cobalt refinement. The pilot facility, with a five-tonne capacity, is designed to refine the process as Xerion prepares for commercial-scale production. The technology converts crude cobalt hydroxide directly into high-purity cobalt metal with notable efficiency.

Laboratory testing demonstrated the technology’s effectiveness, achieving over 99% pure cobalt metal with yields exceeding 98%, producing more than 100 kilograms. This performance surpasses traditional refinement methods, offering a more efficient and cost-effective solution. Xerion CEO and co-founder John Busbee stated: “Our technology is not just an incremental improvement – it is a fundamental reimagining of how we produce critical minerals. At Xerion we are passionate about the advancement of a domestic battery materials supply chain.”

The launch aligns with efforts to strengthen U.S. capabilities in critical mineral production, as the country currently lacks domestic cobalt refining capacity. The technology addresses the reliance on complex global supply chains for minerals vital to defense and commercial applications, supporting the development of a more self-sufficient supply chain.

The DirectPlate MSE process also delivers environmental advantages. Operating at low temperatures, it significantly reduces electricity consumption and simplifies permitting for commercial expansion. The closed-loop rinse system minimizes water usage, and the absence of organic solvents contributes to a reduced emissions profile, enhancing the sustainability of the refining process.

Busbee further noted: “We are proud to be addressing a critical national security challenge by presenting a solution that can significantly reduce our dependence on foreign mineral supplies.” The technology’s environmental and operational benefits position Xerion as a key player in advancing sustainable mineral processing.

Xerion’s pilot-scale production in Dayton represents a milestone in establishing a robust domestic supply chain for battery materials. By leveraging its innovative technology, the company aims to meet growing demand for high-purity cobalt while promoting environmentally responsible production practices.