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Falcon Energy Materials said it has begun constructing its pilot graphite processing facility within the Fluoralpha SA industrial zone in Morocco, marking a strategic milestone in the company’s plan to become a fully integrated supplier of battery-grade anode materials.
The pilot plant, located near Jorf Lasfar, benefits from direct access to world-class port infrastructure, competitive operating costs, and proximity to key European and North American markets. The construction contract for the facility has been awarded to Open Steel, with initial steel deliveries expected in early September and building completion scheduled for November.
“This pilot plant is more than a sample production site,” said Falcon CEO Matthieu Bos. “It represents a critical step toward establishing a large-scale anode production facility and securing a reliable, diversified supply of essential materials for the global battery industry.”
The facility will produce coated spherical purified graphite (CSPG), a key component in lithium-ion batteries. Falcon has already acquired all necessary equipment to begin large-scale sample production for potential clients. The plant will be assembled and tested in China before being shipped to Morocco.
The pilot plant is a precursor to Falcon’s planned commercial facility, which will have an annual production capacity of 25,000 tonnes of CSPG and is projected to generate $152 million in EBITDA annually, with a margin of 62%. The company’s vertically integrated model spans from graphite mining in Guinea to high-value conversion in Morocco.
Falcon’s investment aligns with Morocco’s broader strategy to become a regional and global hub for electric vehicle (EV) battery production. The country is leveraging its strategic location, abundant mineral resources, and robust automotive manufacturing base to attract major international players in the battery value chain.
Morocco is already Africa’s leading car producer as it has also set ambitious targets to produce 100,000 EVs by 2025 and 600,000 by 2030.
Key to this transformation is Morocco’s vast phosphate reserves, which are essential for lithium iron phosphate (LFP) batteries. The country is also developing cobalt refining capacity.
Major investments include a $6.4 billion gigafactory by China’s Gotion High-Tech in Kenitra, and a joint venture between LG Chem and Huayou Group to produce LFP cathode materials
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