Xerion Advanced Battery has begun pilot-scale production at its Dayton, Ohio facility, deploying its proprietary DirectPlate Molten Salt Electrolysis (MSE) technology to refine cobalt. The new process allows crude cobalt hydroxide to be converted directly into high-purity cobalt metal in a single, continuous step, streamlining a procedure that typically involves multiple complex stages.
The pilot facility has a five-tonne annual capacity and will be used to optimize the process ahead of planned commercial-scale expansion. In laboratory testing, Xerion’s technology has achieved cobalt purity above 99% with yields exceeding 98%, producing more than 100 kilograms-results that surpass those of conventional methods.
Xerion’s DirectPlate MSE technology was originally developed for battery component manufacturing, but its application to cobalt refinement comes at a time when the United States lacks domestic refining capacity and relies heavily on imports. Currently, China is responsible for 72% of global cobalt refining, while the US depends on complex supply chains for critical minerals used in batteries, defense, and industrial applications.
The company highlights several environmental advantages of its process. The low-temperature operation reduces electricity needs, while a closed-loop rinse system minimizes water use. The absence of organic solvents further improves the emissions profile and reduces permitting risks for commercial development.
Xerion’s CEO, John Busbee, described the technology as a fundamental reimagining of mineral production, emphasizing its potential to strengthen the US battery materials supply chain and address national security concerns by reducing reliance on foreign sources. The company plans to scale up from pilot to commercial production, aiming to help secure a domestic supply of refined cobalt as demand for critical minerals continues to grow.
