US lithium-ion (li-ion) battery recycling company Blue Whale Materials has achieved mechanical completion of its full processing line at its Bartlesville, Oklahoma facility, having started with commissioning the line earlier this month.

The full line gives Blue Whale the capability to process li-ion battery cells, modules, and packs through its proprietary Blacksand technology in a single integrated operation.

Blacksand is a thermally treated, high-grade black mass that carries nickel, cobalt, and lithium recovered from end-of-life batteries and production scrap.

With cells, modules and packs all running through one line, Blue Whale can now comprehensively serve domestic customers at scale and grow the production of critical minerals for the US supply chain.

The milestone marks completion of the first phase of the company’s Department of Energy expansion grant at Bartlesville, which increases yearly processing capacity from 14 000 t to 20 000 t of battery feedstock with the addition of full line capabilities.

"Mechanical completion is the milestone that turns on full capabilities. The team built and closed out the full line while the baseline operation kept running and kept shipping.

"Commissioning is underway, and our focus now is bringing the line to rate and continuing our expansion. Coupled with the team’s recent fundraising close, the full line gives us the platform to serve our customers with responsible and safe recycling services and high-quality Blacksand for the domestic supply chain of critical minerals," comments Blue Whale CEO Jack Johnson.

Investment firm Ara Partners partner Cory Steffek adds that Blue Whale's successful commissioning of an integrated line capable of handling complete battery packs through to individual cells marks the transition from promising technology to essential commercial infrastructure.

"Reaching 20 000 t of capacity solidifies Blue Whale's position as a cornerstone of the domestic critical minerals supply chain," Steffek states.

Commissioning of the full line is expected to continue through the balance of the year as the facility ramps to its expanded capacity.