A former silver mining region in northern Ontario has been chosen to host North America’s inaugural battery-grade cobalt refinery. The nearby town, appropriately named Cobalt, appears set to align with its namesake. The plant, once operational, will convert mined cobalt rock into cobalt sulfate, a key component in lithium-ion batteries used in a variety of devices, from electric vehicles and smartphones to military aircraft.
Electra Battery Materials, the company spearheading the initiative, aims to have the facility running at full capacity by the close of 2027, capable of yielding 6,500 tonnes of battery-grade cobalt annually — enough to power around one million electric vehicle batteries yearly. CEO Trent Mell emphasized the increasing necessity for critical minerals in modern society, not only for vehicles and grid storage but also for national security reasons.
The refinery’s lab, overseen by Graham Kinsman, Electra’s metallurgical lead, is actively refining chemical and physical processes to eliminate impurities like iron and copper from the cobalt. This meticulous approach results in a highly purified cobalt form that enhances battery stability and longevity.
Despite Cobalt’s historical ties to silver mining, the refinery will import cobalt rock from overseas rather than utilizing local or domestic sources. The town was named after the discovery of cobalt during the construction of the Temiskaming and Northern Ontario Railway in 1903, though silver was the primary focus during that era, leading to a significant silver rush until the 1920s.
While mining companies have explored cobalt prospects in the old silver mines over the past decade, no sustainable veins have been found as of yet. Electra, formerly First Cobalt Corp., shifted its focus to revamping a former metals refinery in the area in 2021.
The cobalt supply will originate from the Democratic Republic of Congo (DRC), a major cobalt mining region, with concerns raised by human rights groups regarding mining practices there. Electra assures steps are being taken to address these issues, including thorough audits at mining sites.
As China dominates the battery-grade cobalt supply chain, Mell aims to replicate China’s model to bolster North American cobalt production. Electra’s objective is to supply a significant portion of the global cobalt sulfate market by next year, with a substantial portion already committed to South Korean company LG Energy Solution. The project has garnered financial support from Canadian and U.S. government entities to bolster domestic critical mineral production and supply chain security.