Simultaneous Lithium Extraction and Thin-Film Deposition of Lithium Metal for a Domestic Supply of Low-Cost, High-Energy Anodes

The U.S. Army’s shift toward electrification faces critical challenges due to a complex supply chain which relies heavily on foreign-sourced batteries and components. This issue is particularly acute for lithium metal (Li-metal) which is essential for high-energy battery production. Today, China controls over 90% of global Li-metal refining capacity, imparting significant geopolitical risk and limiting the Army’s operational resilience. While the United States has significant lithium resources in both brine, hardrock, and produced water form, it is responsible for only 1% of lithium production. Li-metal is fundamental to both non-rechargeable batteries, widely used in Army communications and munitions, and emerging rechargeable batteries that power soldier-carried devices and unmanned aerial vehicles (UAVs). The growing demand for high-energy, lightweight batteries underscores the Army’s need for a secure, efficient, and domestically sustainable Li-metal supply chain. Alpha-En proposes to advance a groundbreaking process termed Reductive Lithium Extraction (RLE) to produce battery-grade Li-metal anodes directly from crude raw materials at room temperature. The RLE process enables direct extraction of Li-metal from water resources. RLE selectively extracts lithium ions from an aqueous solution through a lithium-selective ceramic membrane and transitions them into an organic electrolyte where they are then reduced and electrodeposited as thin-film Li-metal on a copper substrate. Compared to traditional methods of Li-metal refining and anode production, this approach promises to reduce cost by as much as 50% and lower greenhouse gas emissions by an estimated 75% compared to other direct lithium extraction methods. By advancing this technology, which leap frogs the global state-of-the-art production, the U.S. has a unique opportunity to lead in the production of low-cost, environmentally friendly Li-metal and secure a significant and long-lasting strategic advantage for the Army’s current and future portable energy storage needs. The project’s objectives are twofold: (1) to implement the RLE process for the production of high-quality Li-metal electrodes tailored for a battery cell currently utilized by the Army, and (2) to develop and test 1.1 Ah cylindrical cells in collaboration with EaglePicher, a current DoD battery supplier, to confirm the quality and suitability of Alpha-En’s lithium metal. This initiative directly supports the Army’s strategic goals, mitigating supply chain vulnerabilities while enhancing domestic production of high-energy density batteries. A fully realized domestic supply chain not only fulfills military requirements but positions the U.S. to lead in global Li-metal production in support of grid and vehicle electrification. Alpha-En’s partnerships with upstream and downstream stakeholders further strengthen this framework, ensuring integration from lithium raw materials to finished battery cells for defense applications.