Blue Whale Materials opens battery recycling plant in Oklahoma

Blue Whale Materials (BWM) has commissioned its first black mass production facility in Bartlesville, Oklahoma, advancing US critical minerals recovery.

Once fully operational, the site will process up to 14 000 tonnes of lithium-ion battery manufacturing scrap annually. It will produce Blacksand, BWM’s proprietary high-purity black mass containing cobalt, nickel and lithium.

The project is part of a broader expansion. BWM is building a full battery recycling line, from cells to packs, which is scheduled to go live in the first quarter of 2026.

‘Commissioning this baseline black mass plant demonstrates our technological leadership in recovering vital battery-grade metals,’ says Robert Kang, co-founder and ceo. ‘It paves the way for our full recycling system, which will further strengthen domestic supply chains and bring sustainable jobs to communities like Bartlesville.’

The facility received a US Department of Energy grant worth more than EUR 55 million. The funding supports a four-year expansion project expected to raise capacity to 50 000 tonnes annually.

BWM also offers logistics, collection and sorting services, as well as testing and grading of end-of-life batteries for reuse or second-life applications.

‘Producing our high-quality Blacksand here in the US is a huge step for BWM to supply critical minerals and offer complete battery lifecycle solutions,’ says David Fauvre, co-founder and chief strategy officer.