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Falcon Energy Materials has commenced construction of its pilot graphite processing plant in Morocco’s Fluoralpha SA industrial zone, marking a key step in its strategy to become a fully integrated provider of battery-grade anode materials.
Situated near the port of Jorf Lasfar, the facility benefits from access to global shipping routes, cost-effective operations, and proximity to major European and North American markets. Construction has been contracted to Open Steel, with steel deliveries starting in September and completion expected by November. “This pilot facility is a vital move toward our goal of building a full-scale anode plant and ensuring a dependable supply of critical materials for the battery industry,” said CEO Matthieu Bos.
The site will produce coated spherical purified graphite (CSPG), a vital input in lithium-ion batteries. Equipment for large-scale sample production has already been secured, with assembly and testing to occur in China before shipment to Morocco. This pilot plant sets the stage for a future commercial facility capable of producing 25,000 tonnes of CSPG annually, expected to generate $152 million in EBITDA at a 62% margin. Falcon’s operations are vertically integrated, sourcing raw graphite from Guinea and processing it in Morocco.
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The project aligns with Morocco’s ambitions to become a regional leader in electric vehicle (EV) battery production. The country, already Africa’s top car manufacturer, aims to produce 100,000 EVs by 2025 and 600,000 by 2030, leveraging its mineral wealth—including phosphate and cobalt—and a strong automotive industry. Major industry investments in Morocco include a $6.4 billion gigafactory by China’s Gotion High-Tech in Kenitra and a partnership between LG Chem and Huayou Group for LFP cathode material production.
