Xerion's innovative electrolysis process extracts high-purity gallium from domestic sources, offering a sustainable alternative to China's near-monopoly on this critical mineral.
• DirectPlate technology can achieve commercial gallium production within 24-36 months using existing equipment platforms.
• The low-temperature process operates at 'oven hot' temperatures, reducing energy costs and eliminating environmental permits.
• Xerion's platform technology can be adapted to refine multiple critical minerals by adjusting process parameters.
Founded in 2010, Xerion Advanced Battery Corp. is developing technologies that directly address U.S. dependence on foreign sources of critical minerals. The company recently announced a major expansion of its refinement portfolio with the capability to refine gallium metal using its proprietary DirectPlate electrolysis technology. Originally developed for the synthesis of advanced battery materials, DirectPlate can extract high-purity gallium directly from domestic ores and bauxite processing waste as a cost-competitive and environmentally safer alternative to conventional multi-plant refining chains.
To learn more about Xerion’s approach and its implications, we spoke with Dr. John Busbee, CEO and Co-Founder of Xerion.
DirectPlate electrolysis was originally developed for battery components. What specific adaptations made it viable for refining gallium from low-concentration domestic feedstocks? How does it compare in efficiency and purity to conventional gallium recovery routes?
Xerion CEO John Busbee: The key adaptation leverages the fundamental electrochemical selectivity of our molten salt process. DirectPlate operates at specific voltages that correspond to precise electron requirements for individual metals, and this voltage selectivity allows us to extract gallium while leaving impurities in the bath.
Our process can economically extract gallium from low-concentration feedstocks, including domestic bauxite tailings and zinc processing waste streams that have traditionally been considered uneconomical using legacy refinement methods. Unlike conventional multi-step processes requiring separate facilities, DirectPlate transforms these low-grade sources directly into high-purity gallium metal in a single continuous operation.
We've also demonstrated the ability to separate problematic contaminants like lead and arsenic that are present in U.S. gallium deposits – a critical capability that addresses major environmental permitting challenges that have historically blocked domestic gallium production.
China's near-monopoly on gallium has created what many view as a strategic chokepoint. In your view, how quickly can domestic processes like DirectPlate scale to a level that meaningfully mitigates US dependence? What are the most immediate barriers to reaching that scale?
Busbee: Based on our cobalt scaling trajectory, we believe DirectPlate can achieve commercially meaningful gallium production within 24-36 months. We're leveraging identical equipment platforms – the same electroplating apparatus that produces cobalt can produce gallium by adjusting process parameters. Our immediate focus is on completing Phase I SBIR validation by Q1 2026, followed by rapid progression to Phase II and commercial demonstration.
The most significant barriers are securing consistent domestic feedstock agreements and establishing integrated supply chain partnerships with downstream gallium arsenide and gallium oxide producers. The consistent support of strong federal policy aimed at advancing U.S. critical minerals supply chain independence is critical as well.
Notably, unlike other critical minerals, gallium's relatively small market size actually works in our favor – meaningful impact requires thousands of tons annually, not hundreds of thousands. We're actively pursuing partnerships and supply agreements at the domestic level as we speak.
How do you envision partnerships with defense agencies influencing the commercialization pathway, and do you anticipate government procurement policies will establish a domestic gallium supply chain?
Busbee: Defense partnerships and federal funding opportunities are accelerating our commercialization timeline significantly. The DLA SBIR award validates not only the vast potential of our technology, but also the strategic imperative we are working to address - gallium is essential for GPS systems, radar, power electronics, and virtually all defence microwave applications. The recent USGS analysis projecting $ 3.4 billion decrease in U.S. GDP if China implemented a total ban on gallium and germanium creates urgency that should translate into supportive policy frameworks and accelerated procurement timelines.
Your recent news release highlights lower electricity requirements, closed-loop water use, and the elimination of organic solvents. Can you quantify how these process advantages translate into cost competitiveness and reduced permitting risks compared to legacy refinement methods?
Busbee: Our low-temperature molten salt process operates at what we call "oven hot" rather than "foundry hot" temperatures, delivering substantial energy savings compared to conventional high-temperature methods. The closed-loop water system eliminates discharge permitting requirements, while requiring zero organic solvents, which means no air emissions permits or hazardous waste handling protocols. These factors combine to reduce both operating costs and capital expenditure for environmental compliance infrastructure.
Most importantly, this environmental profile enables siting flexibility – we can locate refinement facilities closer to end-users or raw material sources, rather than in remote industrial zones, reducing transportation costs and supply chain complexity. While we’re unable to disclose specific cost metrics, our process economics enable cost parity with Chinese suppliers while meeting U.S. environmental standards—a combination that has historically been impossible with conventional refining methods.
Xerion is now active in both cobalt and gallium refinement. How do you prioritize which minerals to target next, and do you envision DirectPlate serving as a general-purpose platform for domestic refinement of other critical elements like germanium or rare earths?
Busbee: Yes, we absolutely view DirectPlate as a platform technology with broad applicability across the periodic table. We've already demonstrated capability with cobalt and gallium, and our patent portfolio covers a range of critical minerals. With that in mind, we're taking a disciplined approach – proving out our commercial viability with cobalt and gallium before expanding to additional minerals. This strategy reduces execution risk while building the operational expertise and supply chain relationships needed for broader platform deployment.
The beauty of our approach is that the same equipment produces different metals by adjusting process parameters – it's like using the same oven to make different products. This capital efficiency uniquely positions Xerion to address multiple supply chain vulnerabilities simultaneously as we scale.
