
Photo courtesy of Electra Battery Materials Corp.
Electra Battery Materials Corp. has completed a feasibility level Class 3 engineering study for the construction of a modular battery recycling facility adjacent to its cobalt sulfate refinery north of Toronto.
The Toronto-based company says the facility will be designed to recover lithium, nickel, cobalt, manganese and graphite from lithium-ion battery (LIB) manufacturing scrap and end-of-life batteries using its proprietary hydrometallurgical process. Electra says its process was developed and validated through a yearlong pilot program that treated black mass sourced from an industry partner.
The next phase of work, funded in part by Natural Resources Canada, will involve operating the recycling process under continuous and semicontinuous conditions to simulate commercial-scale throughput.
“We are advancing a clear pathway to a closed-loop, domestically sourced battery materials supply chain,” Electra CEO Trent Mell says. “Cobalt recovered at the recycling facility will feed directly into our adjacent cobalt sulfate refinery, which is already in advanced construction, and other critical minerals will be returned to the battery supply chain. This integration strengthens North America’s energy security and positions Electra as a first mover in the continent’s emerging battery ecosystem.”
Building synergy
Electra's cobalt stream will serve as feedstock for its permitted cobalt sulfate refinery, which has received financial backing from both the Canadian government and the U.S. Department of Defense. The company says its partnership with Aki Battery Recycling, a joint venture with the Three Fires Group, will provide a reliable and secure supply of black mass feedstock.
Aki, a majority Indigenous-owned recycling venture, is building a battery collection and shredding operation focused on responsible recycling of LIB manufacturing scrap. Electra says this upstream supply chain security supports both its short-term demonstration efforts and long-term commercial ambitions.
“Through Aki, we are building a robust pipeline to process battery manufacturing scrap and end-of-life batteries that can be converted into value added materials right here in Ontario,” Mell says. “Together with our partners, we are aligning innovation, sustainability, and Indigenous economic development to meet global demand for critical minerals while ensuring the battery supply chain is built on shared prosperity and long-term stewardship.”
The path forward
Electra plans to present the results of the engineering study to downstream partners, including battery manufacturers and original equipment manufacturers (OEMs), which the company claims have expressed interest in participating in the project.
“Their input will help determine the optimal scale of the facility and influence project timing, capital requirements and potential offtake arrangements,” the company says.
The study was completed in partnership with Singapore-based Green Li-ion, whose modular technology underpins the recycling process. Several process modifications and enhancements were developed during the collaboration, Electra says, resulting in proprietary improvements it believes will strengthen its competitive position in the recycling value chain.
Electra says it supports North American energy independence in response to growing global competition, particularly in the face of China’s dominance in critical mineral processing and battery supply chains. As gigafactory timelines evolve and the battery market rapidly expands, the company says its ability to refine cobalt and other critical materials will be a key contributor to this transformation.
The company says its integrated black mass refining program aligns with strategic priorities in Canada and the U.S., as cobalt, in particular, plays an essential role in a wide range of products, from electric vehicles (EVs) to grid storage, military-grade batteries, communication systems and backup power.
“By recycling critical minerals domestically, with batteries already in North America, Electra is helping to close the loop on strategic minerals that are currently largely exported to Asia for processing,” the company says.
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