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The U.S. doesn’t refine cobalt. This startup wants to change that.

April 23, 2025 | by AI

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America’s Cobalt Crisis: This Gutsy Startup is Rewriting the Rules of Battery Warfare

The Dirty Secret Behind Your EV’s Battery

Cobalt isn’t just another metal – it’s the blood diamond of the clean energy revolution. While powering everything from Tesla’s to Tomahawk missiles, 72% of global refining happens in China, with most raw material coming from Congo’s controversial mines. This isn’t just an environmental nightmare – it’s a national security time bomb.

“China’s already shown they’ll weaponize critical minerals. The question isn’t IF they’ll cut us off, but WHEN.”

John Busbee, Xerion CEO (to TechCrunch)

How One Ohio Startup is Fighting Back

Xerion Advanced Battery Corp just dropped a game-changer: single-step cobalt refining using electricity and molten salt. Their Dayton pilot facility (launching NOW) can produce 5 metric tons – small globally but MASSIVE for military needs.

  • Military-Grade Purity: Their process creates cobalt so clean it makes aerospace engineers drool
  • Cost-Competitive TODAY: “We’re already toe-to-toe with China at pilot scale” – Busbee
  • 2,000-Ton Capacity Coming: Next-gen plant will supply 20-40% of U.S. aerospace needs

Why This Matters More Than You Think

This isn’t about making cheaper iPhones. The Pentagon runs on cobalt – from drone batteries to jet engine alloys. Right now, if China turns off the tap:

  • U.S. missile guidance systems stop working
  • Military drone fleets get grounded
  • F-35 production lines screech to a halt

“We accidentally solved cobalt refining while building better batteries. Sometimes the best discoveries come from the side door.”

Busbee on Xerion’s breakthrough

The Bottom Line

Xerion’s move isn’t just business – it’s economic warfare defense. As trade wars escalate, America finally has a homegrown answer to the cobalt crisis. Small start? Absolutely. But in the high-stakes game of mineral dominance, this Ohio startup just dealt America its first winning hand in decades.

Image Credit: RDNE Stock project on Pexels

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