A $450 million
cobalt processing plant is being developed in Arizona to be powered by a 28 MW
150-acre solar farm. It will process cobalt metal, cobalt hydroxide, and cobalt
sulfate from the Democratic Republic of the Congo (DRC). It will be the first
facility of its kind in the U.S. The solar array will be built through 2027.
Company EVelution Energy is developing the project. Earlier this month, its
President & CEO noted:
“Today’s groundbreaking marks another important
milestone in our effort to rebuild America’s domestic critical minerals
processing capability, and we’re proud to be taking that next step here in Yuma
County,” said Navaid Alam, President & CEO, EVelution Energy.
“The piles going into the ground mark the beginning of
the renewable energy system that will power the first cobalt metal and cobalt
sulfate processing facility in the United States. We’re equally proud that
we’re building this project around 100% American-made structural steel,
American engineering and American manufacturing,” Alam added.
When the facility reaches
full commercial operation by the end of 2029, it will process 24,000 metric
tons of raw cobalt hydroxide feedstock each year. That amounts to about 20,000
metric tons of battery-grade cobalt sulfate and 3,000 metric tons of alloy-grade
cobalt metal. It is expected to meet 40% of the projected U.S. cobalt demand.
The project is expected to
use U.S. labor and materials exclusively and provide up to 6200 jobs over its
lifespan. The plant will also be powered by battery storage of excess solar
generation. Ground was broken for the construction of the solar farm earlier
this month, and the plant is expected to be operational in 2029.
The project is dependent on a
reliable water supply. That supply has been obtained according to the results
of drilling and testing a deep groundwater aquifer recently. The new water
source removes one of the project’s biggest technical uncertainties. The
company noted that hydrogeological testing confirmed aquifer zones that can
supply the project’s expected water needs throughout its operating life and
could also support future production expansion.
Interesting Engineering
notes:
“Hydrogeological consultant BasinWells Associates
supervised drilling to a depth of about 1,500 feet beneath the project site.
Engineers carried out aquifer testing, groundwater sampling, and geological
analysis before confirming sufficient groundwater capacity for the planned
operation.”
The water was tested at high
salinity and will be treated before use.
“The company expects the results to inform the final
design of production wells, water treatment systems, and recycling
infrastructure as work continues on its Bankable Feasibility Study. The project
site sits outside one of Arizona’s Active Management Areas, where groundwater
withdrawals face stricter regulation. Although the site’s wells must still
comply with state registration and reporting requirements, they are not subject
to volumetric pumping limits.”
The company plans to deploy a
closed-loop water management system and recycle the water. They expect to
recycle about 70% of the process water and eliminate on-site process-water
discharge. Tailings will not be stored onsite but transferred to licensed facilities
for disposal.
“Net freshwater demand is expected to average about 34
acre-feet each month, or roughly 408 acre-feet annually. According to the
company, that is comparable to the annual irrigation needs of about 70 acres of
farmland in Yuma County.”
“Engineers also plan to use enclosed material handling
systems and modern emissions controls. Together, those features aim to make the
facility one of North America’s most water-efficient critical minerals
processing plants.”
The Export-Import Bank of the
United States is expected to support the project. Construction on the
processing facility is set to begin in early 2027. The project is expected to
generate $1.2 billion in annual economic activity. This project is important as
a domestic mineral processing project that relieves some dependence on China,
the world’s leader in mineral processing.
References:
First
US commercial-scale solar-powered cobalt plant targets 70% water recycling. Aamir
Khollam. Interesting Engineering. July 27, 2026. First
US commercial-scale solar-powered cobalt plant targets 70% water recycling
28 MW
solar project underway to power America’s first commercial cobalt refinery: This
150-acre solar site will power the company’s planned $450 million cobalt
processing facility. Mrigakshi Dixit. Interesting Engineering. July 2, 2026. 28-MW
solar plant to power cobalt processing facility in the US
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