A revolutionary microwave plasma technology is transforming the critical minerals production industry, offering a cleaner and more sustainable alternative to traditional methods.
The production of critical minerals and materials is a complex process that often results in toxic byproducts and environmental hazards. However, a new technology developed at MIT is changing the game by using microwave plasma to transform the way these materials are processed.
Critical minerals are a group of essential elements required for the production of advanced technologies, including renewable energy systems, electronics, and transportation.
These minerals are often found in limited quantities and are essential for modern society's functioning.
Examples of critical minerals include lithium, cobalt, graphite, and rare earth elements.
The increasing demand for these minerals has led to concerns over supply chain security, environmental impact, and social responsibility.
Microwave Plasma Technology: A Game-Changer for Critical Minerals Production
6K, a company founded by former MIT research scientist Kamal Hadidi, is leading the charge in bringing critical materials production back to the U.S. without toxic byproducts. Their technology, called UniMelt, uses beams of tightly controlled thermal plasma to melt or vaporize precursor materials into particles with precise sizes and crystalline phases.
Microwave plasma technology utilizes high-frequency electromagnetic waves to generate and sustain plasma, a gas-like state of matter.
This process involves directing microwave energy at a gas, typically argon or helium, causing it to ionize and create a plasma.
The resulting plasma can be used for various applications, including surface treatment, sterilization, and materials processing.
Microwave plasma technology offers advantages such as high efficiency, precise control, and reduced environmental impact compared to traditional plasma generation methods.
UniMelt has several advantages over traditional production techniques. It can eliminate several high-energy steps of conventional processes, reducing production times from days to hours in some cases. Additionally, it works with recycled feedstocks, making it a more sustainable option for batteries and certain critical minerals.
Scaling Domestic Production
Today, 6K’s additive manufacturing arm operates out of a factory in Pennsylvania, producing about 400 tons of material per year. The company also has a 33,000-square-foot battery center in North Andover, Massachusetts, where it produces battery cathode materials for its energy storage and mobility customers.
However, the company is not stopping there. It is building a 100,000-square-foot production facility in Jackson, Tennessee, which will begin construction later this year. This facility will be used to produce battery cathode materials and represents a massive step up in throughput, with the ability to produce 13,000 tons of material annually.
Battery production has significantly increased in recent years, driven by growing demand for portable electronics and electric vehicles.
According to the International Energy Agency (IEA), global battery production reached 130 million units in 2020, up from just 1 million in 2008.
China is currently the largest producer of batteries, accounting for over 50% of global output.
Lithium-ion batteries remain the dominant type, with an estimated 90% market share.
As demand continues to rise, manufacturers are investing heavily in automation and recycling technologies to improve efficiency and reduce waste.
A Circular Economy
The 6K team says its technology can also create a variety of specialty ceramics, advanced coatings, and nanoengineered materials. They say it may also be used to eliminate ‘forever chemicals,’ though that work is at an early stage.
In addition, the company recently received a grant to demonstrate a process for recycling critical materials from military depots to produce aerospace and defense products, creating a new value stream for these materials that would otherwise deteriorate or go to landfill. This work is consistent with the company’s motto, ‘We take nothing from the ground and put nothing into the ground.’
A Bright Future
The future looks bright for 6K and its microwave plasma technology. With the ability to produce critical minerals and materials without toxic byproducts, the company is poised to make a significant impact on the industry. As Hadidi says, ‘I’m happy if what I started brings something positive to society, and I’m extremely thankful to all the people that helped me.’
