Blue Whale Materials expansion accelerates US battery recycling capacity

Blue Whale Materials expansion strengthens US battery recycling infrastructure

Blue Whale Materials expansion marks a major step for US lithium-ion battery recycling.
The company opened its first recycling facility in Bartlesville, Oklahoma, in August 2025.
The site processes 14,000 tons annually and produces a proprietary material called Blacksand.

Blacksand contains lithium, cobalt, and nickel for refiners and battery manufacturers.
As a result, Blue Whale Materials expansion supports domestic critical mineral recovery.
The facility serves electric vehicles, energy storage systems, and industrial battery markets.

Meanwhile, Ara Partners-backed Blue Whale Materials secured a $55 million DOE grant.
This funding supports long-term expansion of its 50-acre Bartlesville campus.
The company plans to execute this growth over the next four years.

Blue Whale Materials expansion targets scale, jobs, and supply security

Blue Whale Materials expansion will raise processing capacity to 50,000 tons annually.
The upgraded site will convert 3.5 times more batteries into Blacksand.
The project will also create more than 100 permanent jobs in Oklahoma.

Company leaders hosted a beam-signing ceremony in November 2025.
Federal and state officials joined local business leaders at the event.
Oklahoma Governor Kevin Stitt has promoted critical mineral investment statewide.

Accordingly, Blue Whale Materials expansion aligns with national security priorities.
The facility recovers cobalt, nickel, lithium, and copper from battery waste.
These metals support EVs, data centers, aerospace, and defense applications.

Advanced processing, testing, and logistics drive expansion strategy

Blue Whale Materials expansion adds new processing lines and pack shredding capabilities.
The first phase comes online in March and handles full battery packs.
Additional lines will steadily increase throughput toward nameplate targets.

The expansion also introduces in-house testing and grading capabilities.
Battery health testing supports second-life applications like energy storage systems.
This capability strengthens circular supply chains and asset recovery rates.

Logistics improvements also play a central role in the expansion plan.
The company is expanding safe storage and fire mitigation systems.
These investments address safety risks linked to lithium-ion battery handling.

SuperMetalPrice Commentary:

Blue Whale Materials expansion reflects accelerating investment in US battery recycling.
DOE funding continues to shape domestic critical mineral supply chains.
Meanwhile, high-quality black mass products attract refiners seeking low-impurity feedstock.
SuperMetalPrice expects battery recycling capacity to grow alongside EV and AI infrastructure demand.