Battery market solutions

Hatch delivers comprehensive solutions for battery material production, supporting clients from concept through detailed engineering for both cathode active materials (pCAM/CAM) and battery anode materials (BAM).

• Notable Clients: UltiumCAM (POSCO/GM), Vianode, Panasonic, Nano One, Duracell, Lyten, Mitra Chem, BASF, Urbix, Graphite One, Syrah Resources, Ingevity and Novonix.
• Hatch Scope:
  • Research and Scale Up: testwork, piloting, demonstration, commercial plant scale-up
  • FEL0–FEL3 studies: scoping, concept, pre-feasibility, feasibility studies
  • FEED engineering for project execution readiness
  • Project execution (FEL 4) including full EPCM delivery, and participation in design-supply models
  • Market studies
  • Financial analysis
  • Permitting support
  • Due Diligence for acquisitions and investments
  • Operational support for process optimization
• Target Products:
  • Cathode Materials: Ni-rich pCAM/CAM, LFP pCAM/CAM
  • Anode Materials: BG anode graphite, spherical coated graphite, Li foil anode, silicon-infused graphite, silicon
  • Integration with battery recycling processes

Select examples:

Cathode active material - Confidential client
We were appointed to perform two roles at the project site in Quebec. In the initial mandate, Hatch performed the detailed design of the “outside-battery-limits” scope (OSBL), which included the site infrastructure, utilities, and buildings as a sub-contractor. Detailed engineering was completed in 2025.
Shortly after this mandate kicked off, the client requested support from Hatch on the “inside-battery-limit” scope (ISBL, or the core manufacturing process), where we were responsible for the integration of the ISBL scope with the OSBL component. We worked closely with equipment suppliers in Asia to review their designs and provide input on compliance with local codes and regulations.
Once nameplate production is reached, the first-of-its-kind in North America plant is expected to produce 30,000 tonnes per year of high-nickel NCM CAM.

Anode active material - Vianode
By 2030, Vianode aims to deliver a world-leading carbon footprint of only 1 kg CO2 emission/kg high-performance, high-quality anode graphite for 3 million EVs annually. The current market average is 20 kg CO2/kg conventional anode graphite. Vianode is in the process of commercializing proprietary graphitization furnace technology and is expected to set a new industry standard for low-carbon production of graphite anode material.
Hatch was appointed by Vianode to prepare a feasibility study and the basic engineering design for Vianode’s first commercial-scale battery-grade graphite anode production facility in North America. Our work includes integration of the core manufacturing process packages, and design of the “balance-of-plant” including the site plan, buildings, on-site infrastructure, and utilities. Vianode and Hatch have completed the basic engineering phase, as the project progresses toward execution.

We deliver end-to-end solutions for battery cell plants, from consulting and permitting to design and oversight of gigafactory construction.

• Notable Clients: QuantumScape, Ford, Freyr, Forge Nano/Battery, Samsung SDI, Lyten, Bathium (Blue Solutions), and multiple confidential partners.
• Hatch Scope:
  • Research and Scale Up: cell design, piloting, commercial plant scale-up, quality certification support
  • FEL0–FEL3 studies: scoping, concept, pre-feasibility, feasibility studies
  • FEED engineering for project execution readiness
  • Project execution: EPCM, PMC services, detailed engineering, plant integrator, interface design and management, equipment installation, code compliance
  • Market studies
  • Financial analysis
  • Permitting support
  • Due Diligence for acquisitions and investments
  • Operational support for process optimization
• Target Products: Li-ion cells (NMC, LFP), solid-state cells, Li-S cells, LMP cells. Forms include prismatic, cylindrical, pouch cells.

Example - Forge Battery Gigafactory

Forge Battery plans to establish a 3-GWh gigafactory in Morrisville, North Carolina, to produce high energy density cylindrical cells and has secured $100 million in funding from the U.S. Department of Energy. Hatch contributed by providing the design FEED for the 3-GWh facility, which includes process design and equipment selections, plant layout and integration (including the dry room), as well as CAPEX/OPEX estimates and control and manufacturing systems architecture.

We help clients close the loop with innovative recycling solutions, from black mass processing to CAM production.

• Notable Clients: Sibanye-Stillwater, VW Group, Cylib, Glencore, Li-Cycle, Altilium, Battery Metals Inc, CirCoLi, Aleon, GreenLIB, Electra Battery Metals, Aurubis, Recyclico, and multiple confidential partners.
• Hatch Scope:
  • Research and Scale Up: bench-scale testing, piloting, commercial plant scale-up
  • FEL0–FEL3 studies: scoping, concept, pre-feasibility, feasibility studies
  • FEED engineering for project execution readiness
  • Project execution: EPCM, PMC services, detailed engineering, plant integrator, interface design and management
  • Market studies
  • Financial analysis
  • Permitting support
  • Technology development and supply
  • Due Diligence for acquisitions and investments
  • Operational support for process optimization
• Target Products: Black mass, battery-grade sulfates, lithium products, Ni-rich pCAM/CAM, LFP.

Example - Altilium

Altilium is a UK-based clean technology group supporting the transformation of the global energy sector from fossil-based to zero carbon. Their vision is for a domestic EV battery supply chain, where the critical minerals powering the energy transition are recovered from recycling existing waste streams, reducing mining and preserving our natural resources.
Hatch has engaged with Altilium for five years to help them develop their critical UK battery recycling projects. We have assisted from initial early conceptual design and laboratory testwork, to completing engineering studies on their major projects. This included scaling up testwork data, process optimization, plant layout development, equipment package development, execution planning, and cost estimation. We have assisted them with their two key commercial-scale projects:

• ACT 3: Black mass to MHP and lithium sulphate, completing the pre-feasibility study
• ACT 4: Feasibility study for a black mass and MHP feed to battery and technical-grade salts project.

We have also assisted with smaller studies working towards Altilium's ultimate vision of an integrated EcoCathode™ battery metals plant, including battery recycling to black mass production, and producing pCAM & CAM products.