Casablanca – Morocco is taking another step toward strengthening its position in the global electric vehicle battery supply chain through the development of a major graphite-processing project at Jorf Lasfar. The initiative, led by Falcon Energy Materials, is expected to support the country’s broader strategy of building an integrated ecosystem for battery manufacturing and advanced industrial materials as international demand for electric vehicles continues to grow.

The project centers on the production of coated purified spherical graphite (CSPG), a critical material used in the anodes of lithium-ion batteries. While much of the global supply currently comes from Asia, the new Moroccan facility aims to provide battery manufacturers in Europe and North America with an alternative source located closer to their markets.

Pilot plant enters a decisive stage

The project has recently reached an important milestone with the completion of the installation of key equipment for a pilot production unit at Jorf Lasfar. The facility is expected to begin operations in the near future after overcoming delays linked to disruptions in global shipping networks.

The delays were largely attributed to logistical challenges affecting maritime transport routes between China and international markets. Geopolitical tensions in the Middle East and congestion across global freight networks slowed the delivery of specialized equipment required for the pilot facility.

According to company officials, those obstacles have now been resolved, paving the way for the launch of pilot operations.

The pilot plant is considered a crucial component of the overall project. Its primary objective is to validate the production process and obtain certifications required by international battery manufacturers. Samples produced at the facility will be tested by potential customers before the company can secure long-term supply agreements.

Industry specialists view these qualification procedures as an essential step because battery manufacturers typically require extensive testing before integrating new materials into their production chains. Successful certification would significantly strengthen the project’s commercial prospects and support the final investment decision for the large-scale industrial facility.

Commercial production planned by 2028

Falcon Energy Materials intends to begin commercial production between the end of 2027 and the beginning of 2028. The project represents an estimated investment of approximately $86 million and is expected to become one of Morocco’s most significant investments in advanced battery materials.

Once fully operational, the plant is expected to produce around 25,000 metric tons of coated purified spherical graphite annually. This material plays a central role in lithium-ion batteries because it is used in the anode component, which stores and releases energy during charging and discharging cycles.

The company believes that the combination of Morocco’s geographic location, industrial infrastructure and trade agreements could create a competitive advantage when supplying battery manufacturers in Western markets.

Partnership supports technology development

A key element of the project is Falcon’s collaboration with the Chinese group Shanshan, one of the world’s leading producers of battery anode materials. The partnership provides technical expertise and commercial support during the qualification and development phases.

The cooperation reflects a growing trend in Morocco’s industrial sector, where international partnerships are helping accelerate technology transfer and strengthen the country’s capabilities in advanced manufacturing activities.

The project also illustrates the increasing interest of global battery-material producers in establishing operations outside traditional Asian manufacturing hubs. As companies seek to diversify supply chains and improve resilience, Morocco has emerged as a potential location for strategic industrial investments.

Jorf Lasfar strengthens its industrial role

The future facility will be located near the Jorf Lasfar industrial platform, one of Morocco’s most important industrial and logistics centers. The company is continuing efforts to finalize the land required for the project, with the planned industrial site expected to cover approximately five to six hectares.

The facility will integrate all stages of graphite processing, including purification, shaping and coating operations, within a single industrial complex. Such integration is expected to improve efficiency and simplify production logistics.

One of the project’s strategic advantages is its proximity to other industrial developments linked to battery materials. Falcon has partnered with Fluoralpha to secure supplies of hydrofluoric acid, a key chemical used during graphite purification.

Because hydrofluoric acid is highly corrosive and difficult to transport over long distances, the two facilities are expected to benefit from close physical proximity, with the possibility of a dedicated pipeline connection between them. This arrangement could improve safety while reducing operating costs.

Supply chain flexibility

The company has also adapted its raw-material sourcing strategy following changes affecting mining permits in Guinea, where Falcon had initially planned to source part of its graphite supply.

Despite those developments, company officials maintain that the project remains secure due to abundant global graphite availability. Significant production capacities in Southern Africa, East Africa and China are expected to provide alternative supply options, reducing dependence on a single source.

The availability of multiple suppliers is considered an advantage at a time when many manufacturers are seeking to strengthen the resilience of their supply chains and reduce exposure to geopolitical or operational disruptions.

Economic potential and future expansion

The project’s economic outlook appears promising. Based on company estimates, production costs could reach approximately $3,500 per metric ton, while selling prices may average around $6,500 per metric ton. These projections suggest a potential operating margin of more than $3,000 per metric ton.

At full production capacity, the facility could generate annual operating earnings estimated at roughly $75 million, a significant figure relative to the project’s initial investment.

Beyond graphite production, Falcon Energy Materials is reportedly evaluating opportunities involving other strategic minerals that play an important role in advanced manufacturing and clean-energy technologies. Among the materials being studied are manganese and tungsten, both of which are used in a variety of industrial applications.

The company’s broader ambitions align with Morocco’s long-term objective of becoming a regional hub for electric mobility and battery manufacturing. Through investments in critical minerals, processing activities and industrial infrastructure, the country is gradually expanding its presence across the battery value chain.

As global demand for electric vehicles continues to increase, projects such as the Jorf Lasfar graphite facility are expected to reinforce Morocco’s role as an emerging center for battery materials production, connecting markets in Europe, Africa and North America while supporting the transition toward cleaner transportation technologies.