Blue Whale Materials Completes Full Battery Recycling Line in Oklahoma

According to company reports, Blue Whale Materials (BWM) has completed mechanical construction of its full battery processing line at its Bartlesville, Oklahoma facility and has begun commissioning the system, marking the first phase of an expansion supported by a U.S. Department of Energy grant.

The integrated line allows BWM to process lithium-ion battery cells, modules and packs in a single operation using its proprietary Blacksand® technology. The process produces black mass containing recovered nickel, cobalt and lithium from end-of-life batteries and battery production scrap.

The expansion increases the Bartlesville facility’s annual battery feedstock processing capacity from 14,000 metric tons to 20,000 metric tons. BWM said the expanded capabilities will allow it to serve domestic customers at a larger scale and increase the supply of recovered critical minerals for the U.S. battery supply chain.

“Mechanical completion is the milestone that turns on full capabilities,” said Jack Johnson, CEO of Blue Whale Materials. He said the company is now focused on commissioning the line, reaching its targeted processing rate and continuing its expansion.

The project was completed while BWM’s existing operation continued processing material and shipping products, according to the company. Johnson also linked the expansion to BWM’s recent fundraising close, saying the combined developments provide a platform for expanded recycling services and Blacksand® production.

Cory Steffek, a partner at Ara Partners, which has invested in BWM, said the integrated line’s ability to process complete battery packs through individual cells represents a step toward larger-scale commercial battery recycling infrastructure.

Commissioning is expected to continue through the end of 2026 as the Bartlesville facility ramps up toward its expanded annual capacity of 20,000 metric tons.

Source: Blue Whale Materials

SUNSHINE Spotlight: Blue Whale Materials has completed its expanded processing line in Oklahoma, raising annual battery feedstock capacity to 20,000 metric tons as commissioning continues.