Battery Recycling Consortium Opens First Commercial Refinery for Critical Minerals in Nevada
RENO, Nev., Nov. 20, 2025 — A multi-stakeholder battery recycling consortium led by American Battery Technology Company (NASDAQ: ABAT) has commenced commercial operations at North America’s first integrated critical minerals refinery, marking a pivotal advancement in domestic battery material production. The facility, which began 24/7 operations this quarter, will process 20,000 metric tons of end-of-life lithium-ion batteries annually, producing battery-grade lithium, nickel, cobalt, and manganese for the U.S. electric vehicle and energy storage markets.
The refinery employs a proprietary “de-manufacturing” process that achieves recovery rates exceeding 95% for critical materials through selective hydrometallurgical processing, a method fundamentally different from conventional smelting or shredding techniques. The feedstock-agnostic system handles diverse lithium-ion battery chemistries from electric vehicles, consumer electronics, and stationary energy storage systems, creating a true circular supply chain for strategic minerals. The consortium’s partners include BASF, major automotive OEMs, and the U.S. Advanced Battery Consortium (USABC), representing Ford, General Motors, and Stellantis.
The facility’s launch addresses a critical supply chain vulnerability: approximately 85% of the world’s critical minerals are refined in China, creating economic and national security risks for Western economies . This concentration threatens U.S. manufacturing goals as domestic battery production capacity scales to meet federal electrification targets. The consortium’s Nevada refinery directly counters this dependency by establishing the first commercial-scale capability to convert domestic battery waste into refined, battery-grade materials that meet stringent automotive quality specifications.
Market data underscores the urgency of this development. U.S. demand for battery-grade lithium compounds is projected to reach 300,000 metric tons by 2030, yet domestic refining capacity currently satisfies less than 5% of this requirement. The global lithium-ion battery recycling market, valued at $9.2 billion in 2024, is expected to grow at a compound annual rate of 25% through 2032. The Nevada facility positions the consortium to capture an estimated $450 million in annual market value while supporting federal initiatives for supply chain resilience.
The refinery has already secured long-term feedstock agreements with tier-one automotive manufacturers and large-scale energy storage operators, ensuring stable input volumes as EV adoption accelerates. In the most recent quarter, the facility processed 70% more battery material than the previous period, demonstrating rapid operational scaling. The consortium has also established offtake contracts for high-purity nickel sulfate and cobalt sulfate with domestic cathode manufacturers, with pricing indexed to benchmark metal prices.
“This facility represents more than technological achievement—it’s the foundation of American energy independence in the EV era,” said Ryan Melsert, CEO of American Battery Technology Company. “By transforming battery waste into domestically sourced, battery-grade materials at commercial scale, we’re providing automakers with a secure, cost-competitive alternative to overseas refining while creating high-skill manufacturing jobs in Nevada. Our 24/7 operations and proven recovery rates prove that sustainable, profitable domestic recycling is not a future concept—it’s happening now.”
The consortium plans to expand operations through a $144 million U.S. Department of Energy grant awarded in 2024 to construct a second facility in the Southeast with 100,000-ton annual capacity. This fivefold scale-up will incorporate next-generation separation technologies currently being validated through the consortium’s innovation partnership with Argonne National Laboratory and Clemson University, targeting even greater efficiency and lower environmental impact.
About the Battery Recycling Consortium
The Battery Recycling Consortium is a strategic partnership of technology developers, automotive manufacturers, and materials companies commercializing integrated lithium-ion battery recycling solutions in North America. Led by American Battery Technology Company, the consortium combines patented de-manufacturing processes with targeted hydrometallurgical refining to produce battery-grade critical minerals from end-of-life batteries. The partnership has received competitive awards from the U.S. Department of Energy and U.S. Advanced Battery Consortium, demonstrating its role in establishing a domestic circular supply chain for strategic battery materials.
Media Contact
Sarha Al-Mansoori
Director of Corporate Communications
G42
Email: media@g42.ai
Phone: +971 2555 0100
Website: www.g42.ai
