Blue Whale Materials Expands Lithium-Ion Battery Recycling Facility in Oklahoma

Blue Whale Materials Expands Lithium-Ion Battery Recycling.

Inaugural Milestone Achieved:
August 2025 marked a significant stride for Blue Whale Materials (BWM) as they opened their lithium-ion battery recycling facility in Bartlesville, Oklahoma. The facility initiated operations with a nameplate capacity of 14,000 tons per year, specializing in the separation and recycling of batteries and production scraps into a high-value output known as Blacksand. This product contains essential elements such as lithium, cobalt, and nickel which are pivotal for the manufacturing of new battery cells.

Funding Fuels Expansion

The company’s ambitious expansion plan is backed by a substantial $55 million grant from the U.S. Department of Energy. This funding, awarded under the Bipartisan Infrastructure Law, is part of a larger initiative totaling approximately $110 million. The expansion aims to enhance the facility’s processing capacity to an impressive 50,000 tons per year by adding additional processing lines and infrastructure improvements scheduled over the next four years. Such advancements bolster BWM’s capability to recycle 3.5 times more materials into high-purity Blacksand, further optimizing the supply chain for lithium-ion batteries.

Job Creation and Economic Growth

These developments are expected to create over 100 permanent jobs, alongside numerous construction positions during the expansion phase. Local leaders, including Oklahoma Governor Kevin Stitt, have supportively highlighted the importance of BWM’s efforts, which align with Oklahoma’s objective to become a pivotal hub for critical minerals. This growth is not only a boon for the local economy but also crucial in reinforcing a self-sufficient supply chain for necessary materials in battery production.

Cutting-edge Recycling Process

At the heart of BWM’s operations is an innovative recycling process that boasts high recovery rates of key minerals. Approximately 98% of cobalt and nickel can be extracted from the battery production scrap, significantly minimizing contaminants typically found in conventional recycling methods. This positions BWM as a leader in providing high-grade inputs for downstream metal refiners and battery manufacturers, and contributes positively toward environmental sustainability and economic circularity.

Ripple Effects on the Future of Energy

David Fauvre, co-founder and Chief Strategy Officer of BWM, emphasizes the dual benefits of their expansion plan: it supports the acceleration of the circular supply chain for batteries while catering to increased demand for electric vehicles globally. Fauvre also noted the importance of their operations to national security, highlighting that domestic supply chains for critical minerals play a vital role in production independence amidst growing geopolitical challenges.

Community Partnerships and Local Impact

BWM’s expansion strategy extends beyond infrastructure; it includes community engagement and workforce development. The company is collaborating with local organizations to enhance education and job readiness, thus ingraining itself deeper into the Bartlesville community. Such initiatives create rippling effects, empowering locals and building a knowledgeable workforce essential for sustainability in the manufacturing and recycling sectors.

Conclusion: A Model for Future Initiatives

The progress of Blue Whale Materials in Bartlesville serves as an exemplary model for the future of battery recycling in the United States. As electric vehicle adoption continues to rise, the demand for innovative recycling solutions is more urgent than ever. BWM’s commitment to expanding operations and fostering community ties will pave the way for more sustainable manufacturing and recycling practices, securing a cleaner, more resilient energy future.