News: Suppliers
25 September 2025
Xerion to extend DirectPlate electrolysis to refining of gallium from domestic US feedstocks
Xerion Advanced Battery Corp of Kettering, OH, USA, which develops and manufactures next-generation battery components and critical minerals, is expanding its critical minerals refinement portfolio after recently demonstrating the capability to refine gallium. Xerion aims to develop the process on a commercial scale to support military and commercial applications, including the production and maintenance of critical defense platforms, as well as semiconductors. To demonstrate the feasibility of this technology, Xerion has been awarded Phase I funding from the US Defense Logistics Agency (DLA) under the small business innovation research (SBIR) program.
With its DirectPlate electrolysis technology, originally developed for the refining and synthesis of battery components, Xerion is developing the capability to refine gallium from several existing and readily available domestic sources containing varying low-level gallium content. The technology may also provide the capability to refine high-purity germanium, depending on the resource. Xerion says that, unlike existing methods that require multiple plants and extensive processing, its DirectPlate approach can transform existing and readily available domestic ores and bauxite processing waste directly into high-purity gallium metal suitable for alloying to semiconductor-dependent materials with what is claimed to be unprecedented efficiency.
“The United States is at a crossroads with respect to critical minerals, and Xerion is committed to the development of technologies capable of paving the way for a dramatic reshaping of existing global supply chains,” says CEO & co-founder Dr John Busbee. “Our nation’s leadership in the defense and semiconductor sectors is directly impeded by a reliance on gallium alloy supply chains dominated by foreign markets like China, and we are passionate about remedying that vulnerability to support domestic industrial development,” he adds. “We look forward to working with the DLA and others as we bring this technology to market.”
Xerion says that, with this new technology, it is poised to reshape the domestic gallium alloys market, propelled by increasing use in semiconductors, optoelectronics and power electronics. Currently, over 98% of global gallium refinement is concentrated in China, and in December 2024 China implemented a ban on exports of gallium and germanium to the USA, creating a single-point-of-failure risk for the USA and its allies. The United States Geological Survey (USGS) issued an updated probability-based estimate of gallium metal interruption in August, which found that a disruption in gallium supply could trigger cascading effects, resulting in $1.4bn in direct economic losses and major setbacks in defense manufacturing. These challenges are compounded by a total lack of domestic production or emergency reserves in the USA, undermining the production and maintenance of critical defense platforms as well as the competitiveness of semiconductor manufacturers.
Xerion claims that its technique for refining gallium metal is immediately cost-competitive with legacy refinement methods, in addition to offering a range of advantages related to environmental impact. This process involves inherently safe low-pressure processing, and drastically reduced electricity requirements compared with conventional refinement methods while minimizing permitting risk for commercial infrastructure development. Xerion’s DirectPlate technique also features a closed-loop water recycling system, delivering significant water use advantages, in addition to requiring no organic solvents, resulting in a low-air-emission and low-flammability profile.
A key element of Xerion’s commercialization pathway for refinement of gallium is participation in the DLA SBIR program, through which the company plans to establish a techno-economic analysis that validates the economic viability of the technology. Xerion expects to conclude Phase I activities by first-quarter 2026, and plans to pursue Phase II and Phase III funding and activities.
The announcement follows Xerion’s recent launch of a pilot production line at its Dayton, Ohio manufacturing facility for the refinement of cobalt metal. Xerion reckons that, together, these announcements position it at the forefront of a critical industry transformation.
US Geological Survey reckons China ban on gallium and germanium exports could cost $3.4bn in US GDP