Chemical & Metal Refining
Chemical and elemental refining is one of the largest industrial consumers of electricity worldwide. Many of these processes are already fundamentally electrochemical, relying on electrolysis, electrowinning, or electrorefining to convert ores and feedstocks into high-purity industrial inputs. With the growth of EVs, batteries, renewables, and semiconductors, these refining processes are under pressure to scale rapidly while decarbonizing. Electrification provides both efficiency and precision, and when powered by renewables, it can significantly reduce the carbon footprint of materials critical to industrial supply chains.
This page highlights three key clusters where electrification plays a central role: Lithium, Nickel & Cobalt Refining, Chlor-Alkali & Electrochemical Processing, and Electrowinning for Copper, Zinc & Rare Earths. Together, they form the backbone of modern electrified industry, linking mining and chemicals to batteries, EVs, and advanced manufacturing.
Lithium, Nickel & Cobalt Refining
These metals are the essential inputs for cathode active materials used in EV and BESS batteries. Refining is highly electricity-intensive, involving leaching, solvent extraction, precipitation, and high-temperature calcination. As demand for NMC, NCA, and LFP chemistries grows, refining capacity and energy sourcing have become bottlenecks in the battery supply chain.
| Process Step | Electrified Equipment | Role | Electrification Advantage |
|---|---|---|---|
| Lithium Extraction & Refining | Electrified pumps, filtration, crystallizers | Converts brines or spodumene ore to lithium carbonate/hydroxide | High electricity demand, can be paired with solar/geothermal |
| Nickel & Cobalt Refining | Electrowinning cells, pressure leach reactors | Produces high-purity nickel sulfate and cobalt sulfate | Electrochemical processes already dominant; renewable sourcing reduces footprint |
| Calcination & Conversion | Electric rotary kilns, plasma or induction furnaces | Converts intermediates into cathode-ready precursors | Electric heating allows precise control and lower emissions vs fossil kilns |
Electrowinning for Copper, Zinc & Rare Earths
Electrowinning and electrorefining use electricity to recover pure metals from leach solutions. They are widely applied to copper, zinc, manganese, and increasingly rare earth elements. Electrowinning is central to mining electrification, as it directly converts ores into refined metals using electric current instead of fossil-based smelting. When powered by renewables, it creates a direct pathway for low-carbon metal supply chains.
| Process Step | Electrified Equipment | Role | Electrification Advantage |
|---|---|---|---|
| Copper Electrowinning | Electrolytic cells, rectifiers, cathode starter sheets | Recovers high-purity copper from leach solution | Avoids fossil-intensive smelting, electricity is the direct energy carrier |
| Zinc Electrowinning | Large electrolysis cells, cathode stripping machines | Extracts zinc from purified sulfate solutions | Electrified cells deliver high recovery and product purity |
| Rare Earth Electrowinning | Experimental electrolysis and molten salt processes | Recovering REEs without fossil smelting | Still at pilot scale, but strategically important for magnets and EV motors |
Chlor-Alkali & Electrochemical Processing
The chlor-alkali process produces chlorine, caustic soda (NaOH), and hydrogen — essential building blocks for chemicals, plastics, and industrial inputs. It is one of the most electricity-intensive industries in the world, consuming large shares of national grids where plants are concentrated. Electrification is intrinsic here: massive membrane or diaphragm electrolysis cells split brine into products, and efficiency gains come from improved cell designs, renewable power sourcing, and digital optimization.
| Process Step | Electrified Equipment | Role | Notes |
|---|---|---|---|
| Brine Electrolysis | Membrane or diaphragm electrolysis cells | Splits brine into Cl2, NaOH, and H2 | Electricity is the core input; renewable sourcing cuts CO2 |
| Product Handling | Electric compressors, pumps, storage tanks | Moves chlorine, hydrogen, and caustic soda to downstream uses | Hydrogen by-product can be captured as green H2 |
Role in Industrial Electrification
- All three clusters — battery metal refining, chlor-alkali, and electrowinning — are inherently electrified processes.
- Decarbonization hinges on renewable power supply, improved efficiency of electrochemical cells, and process optimization.
- Electrowinning and refining tie mining directly into electrification strategies, displacing fossil smelting with electricity.
- These processes represent some of the largest single-site industrial electricity loads, making them natural candidates for renewable PPAs and microgrids.
Strategic Importance
- Directly tied to EV and battery supply chains (lithium, nickel, cobalt, copper).
- Forms the industrial base for chemicals, plastics, semiconductors, and renewables.
- Massive power users — their shift to renewables has system-wide impacts on grids.
- Electrochemical innovation (membranes, catalysts, digital twins) will further reduce energy intensity.
Key Global Refiners & Producers
The following table highlights leading companies across the three main refining clusters — lithium/nickel/cobalt refining, chlor-alkali electrochemical processing, and copper/zinc/rare earth electrowinning. These players represent the industrial backbone of electrified refining and are key to scaling low-carbon supply chains for EVs, batteries, and clean energy systems.
| Cluster | Key Companies | Notes |
|---|---|---|
| Lithium Refining | Albemarle, SQM, Ganfeng Lithium, Tianqi Lithium, Livent | Leaders in lithium carbonate/hydroxide from brines and spodumene; U.S., Chile, China, Australia dominate supply |
| Nickel & Cobalt Refining | Glencore, Vale, Norilsk Nickel, Huayou Cobalt, Sumitomo Metal Mining, Jinchuan Group | High-purity nickel sulfate and cobalt sulfate for EV cathodes; refining concentrated in China, Russia, Canada |
| Chlor-Alkali Processing | Olin Corporation, Westlake Chemical, Formosa Plastics, INEOS, Tata Chemicals | Large membrane cell operations producing chlorine, caustic soda, and hydrogen by-product; high electricity intensity |
| Copper Electrowinning & Electrorefining | Freeport-McMoRan, Codelco, BHP, Southern Copper, KGHM | Operate some of the world’s largest copper electrowinning and electrorefining facilities in Chile, U.S., and Peru |
| Zinc Electrowinning | Nyrstar, Teck Resources, Boliden, Hindustan Zinc, Korea Zinc | Global leaders in zinc sulfate refining and electrowinning; electrified plants with significant grid demand |
| Rare Earth Refining | China Northern Rare Earth Group, Lynas Rare Earths, MP Materials | Pioneering rare earth separation and emerging electrowinning processes; dominated by China with diversification underway in U.S./Australia |