Battery Materials Processing & Refineries
Cathode and anode materials are the core of lithium-ion batteries, defining energy density, cost, cycle life, and safety. Cathodes (such as LFP, NMC, and NCA) drive much of the pack’s capacity and performance, while anodes (primarily graphite today, with silicon blends emerging) determine charging speed, cycle stability, and safety margins. Together, they represent the most strategic layer of the battery supply chain, requiring refined, high-purity inputs and advanced processing to meet the demands of EV gigafactories worldwide.
EVs use NCM, NCA, and LFP chemistries; storage applications use NCM (on-grid) and LFP (off-grid); and solar applications using LFP.
Battery-Grade Materials
Battery-grade chemicals are refined precursors, providing the feedstock for cathode and electrolyte production. Their purity and consistency directly affect cell performance and safety.
| Material | Refined Form | Major Producers | Constraints |
|---|---|---|---|
| Lithium | Lithium carbonate, lithium hydroxide (LiOH) | China (Tianqi, Ganfeng), Albemarle (Chile/US), SQM | >70% refining capacity in China; hydroxide demand growing for high-nickel CAM |
| Nickel | Nickel sulfate (NiSO4) - HPAL, MHP feedstock | Indonesia (HPAL projects), China, Russia, Canada | ESG challenges from HPAL; export restrictions (Indonesia) |
| Cobalt | Cobalt sulfate (CoSO4) | China, DRC (via Chinese refiners), Finland | Supply highly concentrated in DRC ? China refining |
| Manganese | Manganese sulfate monohydrate (MnSO4) | China, South Africa, Gabon, pilot plants in EU/US | High-purity supply limited; scale-up underway |
Cathode Active Materials (CAM)
CAM is the engineered powder that forms the positive electrode in a lithium-ion cell. CAM design defines energy density, cost, and cycle life. CAM production is highly concentrated in China, Korea, and Japan, with new capacity being built in Europe and North America.
| CAM Type | Composition | Producers | Notes |
|---|---|---|---|
| NMC* (Nickel Manganese Cobalt) | Varied Ni:Mn:Co ratios (622, 811) | Umicore, BASF, LG Chem, CATL | High energy density; cobalt content still a concern |
| NCA (Nickel Cobalt Aluminum) | Ni-Co-Al blends | Panasonic/Tesla, Sumitomo Metal Mining | High-nickel, high-energy; safety challenges |
| LFP (Lithium Iron Phosphate) | LiFePO4 chemistry | BYD, CATL, Valence, U.S./EU pilot lines | Low cost, safer, cobalt-free; lower energy density |
| LMFP (Lithium Manganese Iron Phosphate) | LiMnFePO4 blends | CATL, Gotion, Chinese pilot projects | Improved energy density vs LFP; emerging scale |
| Solid-State Cathodes | Sulfides, oxides, composites (R&D) | Toyota, QuantumScape, Solid Power | Pre-commercial; promise of higher density & safety |
Battery Anode Materials
Anode materials are the negative electrode in lithium-ion batteries, storing and releasing lithium ions during charge and discharge. While cathode active materials (CAM) define much of the energy density and cost, anodes are equally critical for cycle life, charging speed, and safety. Today’s EV anodes are dominated by graphite — both natural and synthetic — with growing use of purified spherical graphite (PSG) and silicon blends to boost performance. Emerging chemistries such as lithium-titanate oxide (LTO) and solid-state designs may diversify anode material demand in the future.
| Material | Examples | Advantages | Constraints |
|---|---|---|---|
| Natural Graphite (Purified Spherical Graphite – PSG) | Processed flake graphite, rounded to 10–30 µm spheres | High tap density, cost-effective, widely used in EV anodes | China dominates refining; environmental concerns with purification |
| Synthetic Graphite | Petroleum coke/coal tar pitch ? graphitized at >2,800°C | High purity, consistent quality, good fast-charging stability | Very energy-intensive; higher cost; carbon footprint concerns |
| Silicon-Enhanced Graphite | Graphite blended with 5–15% silicon or SiOx | Higher capacity (~3,500 mAh/g vs 370 for graphite); improves energy density | Volume expansion during cycling; cycle life challenges; higher cost |
| Lithium-Titanate (LTO) | Spinel Li4Ti5O12 | Exceptional safety, fast charging, long cycle life | Lower energy density; niche applications (buses, heavy-duty fleets) |
Why They Matter
Battery-grade refining and CAM production are the most strategic chokepoints between raw mining and gigafactory cell assembly. Control of these midstream assets determines which regions can secure battery supply chains. Without localized BG/CAM refining, even domestic mines cannot feed regional gigafactories efficiently. Securing diversified supply of both natural and synthetic graphite for anodes is considered as strategic as cathode supply in the midstream battery chain.
Supply Chain & Risks
Refining capacity is overwhelmingly concentrated in China, which processes ~60–90% of global lithium, cobalt, graphite, and manganese feedstocks. Nickel refining is growing in Indonesia but faces ESG and export-policy challenges. Western supply chains are racing to build BG and CAM refineries in the U.S., EU, and allied countries to comply with IRA and EU Critical Raw Materials Act requirements. Risks include long lead times (3–5 years for refineries), high capex, permitting hurdles, and IP concentration in Asian firms.
Over 90% of PSG refining capacity is in China, creating dependency risks for natural graphite. Synthetic graphite is dominated by Chinese and Japanese suppliers and carries a heavy carbon footprint. Silicon additives are supplied by specialized chemical companies and remain expensive. U.S., EU, and Australian projects are moving to establish local PSG and synthetic graphite refining capacity under critical minerals strategies.
CAM refineries
List of the major refineries for processing battery-grade lithium, nickel, cobalt, and manganese for making batteries for electric vehicles, storage, and solar. These minerals and metals are the most critical (active) materials in making EV batteries.
| Refinery | Product | State |
|---|---|---|
| 6K | LFP, NMC811 | MA |
| Albemarle | Lithium hydroxide | NC |
| Alionyx Energy | Redox active polymers | CA |
| American Battery Technology Company | Lithium hydroxide | NV |
| Ascend Elements | NMC | MI |
| Ascend Elements | NMC | KY |
| BASF Elyria Lithium | Lithium carbonate | OH |
| BASF Toda America | LMO, NMC | MI |
| Controlled Thermal Resources | Lithium hydroxide | CA |
| Eagle Lundin Humboldt Mill | Nickel | MI |
| ICL-IP America Inc. | LFP | MO |
| Ioneer | Lithium hydroxide | NV |
| Lanxess-Standard Lithium | Lithium carbonate | AR |
| Lanxess-Standard Lithium | Lithium carbonate | AR |
| Lithium Americas | Lithium carbonate | NV |
| Livent | Lithium hydroxide | NC |
| Missouri Cobalt | Cobalt | MO |
| Mitra Future Technologies | LFP | CA |
| Piedmont Lithium | Lithium hydroxide | NC |
| Piedmont Lithium | Lithium hydroxide | TN |
| Primet Precision Materials | cathode materials | NY |
| Talon Nickel | Nickel | ND |
| Tesla | Lithium hydroxide | TX |
| The Metals Company | Cobalt, nickel sulfate | TX |
Anode material (graphite) refineries
| Refinery | Product | State |
|---|---|---|
| Advano | Silicon | LA |
| Alabama Graphite | Natural graphite | AL |
| Alkegen | Si-graphite composite | IN |
| Amprius Technologies | Silicon nanowire anode | CA |
| Amsted Graphite | Natural graphite | WV |
| Anovion | Synthetic graphite | NY |
| Anovion Spokane | Graphite | WA |
| Applied Materials | Lithiated anodes | CA |
| Birla Carbon | Synthetic graphite | LA |
| Birla Carbon | Synthetic graphite | GA |
| Enevate | Si-graphite composite | CA |
| Graphex | Spherical graphite | Mi |
| Graphite One | Graphite | WA |
| Group14 Technologies | Si-graphite composite | WA |
| Li-Metal | Graphite | NY |
| Libama | advanced metal anode | TN |
| NanoGraf | Si-graphene composite | IL |
| Nanotech Energy | Graphene | CA |
| Novonix | Synthetic graphite | TN |
| Paraclete Energy | Silicon | MI |
| SGL Carbon | Natural graphite | NC |
| SGL Carbon | Natural graphite | CA |
| SGL Carbon | Natural graphite | PA |
| SGL Carbon | Natural graphite | PA |
| Sila Nanotechnologies | Si-graphite composite | CA |
| Superior Graphite | Synthetic graphite | IL |
| Superior Graphite | Synthetic graphite | IL |
| Syrah Technologies | Graphite | LA |
Market Outlook & Adoption (Cathode + Anode)
| Rank | Trend | Adoption Drivers | Constraints |
|---|---|---|---|
| 1 | LFP (Lithium Iron Phosphate, Cathode) | Low cost, safe, cobalt-free; mass adoption in China and global mid-market EVs | Lower energy density vs nickel-rich chemistries |
| 2 | Purified Spherical Graphite (PSG, Anode) | Dominant EV anode material; cost-effective; scalable supply (China-led) | China refining dependency; ESG concerns |
| 3 | NMC Cathodes (622 / 811) | High energy density; widely used in premium EVs | Cobalt/nickel supply volatility; higher cost |
| 4 | Synthetic Graphite (Anode) | Stable cycling; fast-charging resilience; consistent quality | Energy-intensive production; carbon footprint; higher cost |
| 5 | NCA Cathodes | High nickel content, high energy density (Tesla, Panasonic) | Safety concerns; supply risks; less adoption outside Tesla |
| 6 | Silicon-Enhanced Graphite (Anode) | Boosts anode capacity and energy density; attractive for performance EVs | Swelling/volume expansion; cycle life limits; high cost |
| 7 | LMFP Cathodes (Lithium Manganese Iron Phosphate) | Improves LFP energy density; manganese widely available | Scaling still limited; performance validation ongoing |
| 8 | LTO (Lithium Titanate Oxide, Anode) | Exceptional cycle life and safety; used in buses and commercial fleets | Low energy density; niche applications only |
| 9 | Solid-State Cathodes & Anodes | Future promise: lithium metal anodes, solid electrolytes; game-changing safety/density | Not commercial; scale-up and manufacturing challenges |
