Miners are leveraging advanced technologies such as machine learning and cutting-edge chemistry to meet the increasing demand for critical materials like copper and graphite in the green technology sector. Back in 2011, Nico Cuevas, an immigrant from Mexico living in Arizona, recognized the need for graphite for Tesla’s electric vehicle battery anodes. Despite owning a graphite mine, Cuevas discovered that the graphite being extracted was not suitable for Tesla’s requirements. Fast forward twelve years, and Cuevas is now the CEO of Urbix, an innovative graphite producer located in Mesa, Arizona. Urbix utilizes machine learning to develop consistent graphite anodes suitable for EV batteries using various natural and synthetic forms of graphite. The company has already secured a deal to supply graphite to South Korean battery and chip maker SK On. Urbix is just one of several American startups that are exploring alternative approaches to secure critical minerals as the supply becomes tighter. Governments and businesses are seeking new sources of these minerals to meet the growing demand from industries like electric vehicles, renewable energy, and electrification infrastructure. While there have been investment announcements, experts predict future shortfalls in critical mineral supplies. Geopolitical tensions and export controls in China, the world’s leading processor and producer of critical minerals, raise concerns about potential disruptions to supply chains for American manufacturers. However, the US government has introduced measures to support domestic production and reduce reliance on foreign sources, such as the Inflation Reduction Act. In addition to traditional methods like searching for new deposits and investing in processing facilities, miners are also embracing innovation to increase mineral yields and even recover materials from existing mine waste. Machine learning has emerged as a promising technique for boosting yields and reducing carbon emissions in critical minerals processing. Graphite, a naturally occurring form of carbon, is particularly crucial for battery anodes in lithium-ion cells. Urbix has employed machine learning to optimize the production process and create a consistent end product, significantly reducing waste compared to traditional methods. The company reports that approximately 80% of the raw material input is utilized in the final product, compared to typical yields of around one-third with traditional methods. With Series C funding, Urbix is currently running a pilot plant and constructing a commercial demonstration facility. Its production target is 28,000 tons per year by 2026, with plans to scale up to 320,000 tons starting in 2032. Urbix will source graphite from various locations, including Latin America, Madagascar, Tanzania, and Northern Europe. Another innovator in the field is Locus Fermentation Solutions, a chemical company based in Solon, Ohio. Locus aims to increase copper yields by introducing bio-surfactants derived from natural sources like yeast. Bio-surfactants are chemicals produced by microbes that decrease the surface tension of materials. By adding bio-surfactants to copper processing methods such as rock soaking and leaching, Locus achieves higher yields and reduces energy consumption. The company claims that its bio-surfactants improve copper yields by 7% and is currently exploring their application to iron ore and tailings waste. Copper is a crucial metal in the transition to green technologies, with electric vehicles requiring six times more copper wiring than traditional vehicles. By improving copper recovery rates and reducing the environmental impact of mining operations, Locus aims to meet the demand for materials while satisfying the expectations of investors, customers, and communities for more sustainable mining practices. Finally, Phoenix Tailings, a startup based in Woburn, Massachusetts, is focused on recovering rare earths from mining waste, also known as tailings. After large-scale tailings dam failures, such as the Brumadinho disaster in Brazil, which caused significant loss of life, there is growing recognition of the environmental risks associated with tailings disposal. Phoenix Tailings sees an opportunity to recover valuable rare earth metals from tailings and contribute to a cleaner and more sustainable mining industry. The company identifies mine sites free from radioactive elements and implements mining and processing techniques to extract the rare earths required for green technologies like electric vehicles and offshore wind turbines. This approach has not been widely applied, but the company believes that numerous mine sites could potentially benefit from this method. By reducing dependence on China, which currently dominates the global supply of rare earths, Phoenix Tailings aims to make a meaningful contribution to the diversification of rare earth sourcing. The company operates a pilot facility in upstate New York and prioritizes zero waste by recycling leftover materials from tailings processing.
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