Aleon Renewable Metals (ARM), established in 2022 and headquartered in Freeport, Texas, is an integrated lithium-ion battery recycling enterprise under the Aleon Metals umbrella company, which has operated since 1973. Specializing in closing the battery lifecycle by recovering critical metals from spent batteries, ARM works to reduce reliance on freshly mined resources while supporting the global transition to renewable energy.
The company focuses on processing end-of-life batteries from electric vehicles (EVs), energy storage systems, and consumer electronics to extract metals such as lithium, nickel, cobalt, manganese, and graphite. These materials are transformed into battery-grade chemicals, including cobalt sulfate, nickel sulfate, lithium carbonate, and cathode active materials (CAM), which are key inputs for new battery production.
Battery Technology
ARM’s technological capabilities are built around advanced recycling and processing methods. Hydrometallurgical techniques extract metals from battery waste via chemical leaching and purification, yielding battery-grade materials like lithium carbonate, cobalt sulfate, and nickel sulfate. Complementing this, pyrometallurgical processes recover metals from residual materials through controlled heating, ensuring a comprehensive recovery rate. These methods minimize waste while maximizing the purity and usability of recovered metals for next-gen battery production.
A standout innovation is ARM’s collaboration with Forge Nano, integrating Atomic Layer Deposition (ALD) technology branded as Atomic Armor. This approach coats cathode materials with ultra-thin protective layers, improving their stability and longevity in batteries. By enhancing battery safety and performance, the technology supports the development of reliable high-capacity EV and energy storage solutions. ARM plans to expand its manufacturing scope to produce precursor cathode materials (pCAM) and final CAM directly from recycled inputs, further streamlining the supply chain. The company’s facility in Texas is designed to process approximately 60,000 tons of battery waste annually, directly contributing to a sustainable materials ecosystem for EV manufacturers.
Recent Projects
In recent years, ARM has prioritized scaling its recycling operations and advancing its production capabilities. By 2024, the company solidified plans to develop a commercial-scale hydrometallurgical facility in Texas, targeting production of up to 60,000 tons of battery-grade materials annually. This facility, when fully operational, will support 35 GWh of renewable energy storage capacity yearly—a significant leap toward bridging the gap between recovered materials and growing EV market needs.
ARM has also intensified its research into expanding into CAM production. Recent engineering milestones include integrating recycled metals into cathode formulations for next-gen batteries, capitalizing on partnerships with technology leaders like Forge Nano. By late 2024, the company announced breakthroughs in refining the ALD-coated cathodes, demonstrating improved energy density and reduced degradation rates in lithium-ion cells. These developments underscore ARM’s commitment to aligning its recycling expertise with cutting-edge battery innovations.
Investors
ARM’s financial backing reflects its position as a critical player in the battery recycling sector. A notable milestone occurred in June 2022, when the company secured $75 million in tax-exempt bonds through investors led by Citibank and the Brazoria County Industrial Development Corporation. This financing supported its facility construction and technological advancements.
Ken Nicholson, CEO of FTAI Infrastructure and a board member for ARM, brings institutional investment expertise through his ties to Fortress Transportation and Infrastructure Investors LLC. These connections have further strengthened ARM’s capital access and operational credibility. The company’s parent organization, Aleon Metals, also provides foundational support through its established metal recycling infrastructure, including partnerships with Gladieux Metals Recycling.
Business Details
Location: Freeport, Texas, USA
Website: https://aleonmetals.com/
LinkedIn: https://www.linkedin.com/sales/company/95690095
