In an effort to strengthen the US silicon metal supply chain and meet forecasted demand in growing industries, such as electric vehicles (EVs), silicon metal and silicon-based alloys producer Ferroglobe is leveraging its extensive history and innovative approaches to increase domestic production capacity, says US corporate affairs and North American business development leader VP Bill Hightower.

Owing to silicon metal’s essential role in manufacturing such critical items as semiconductors, aluminium, solar, body armour and aerospace components, silicon metal has been officially recognised as a critical mineral in Canada, and a critical material in the US, he explains.

In addition, silicon metal is also “reshaping the lithium-ion battery industry” in the EV sector, says Hightower.

Currently, EV batteries extensively rely on graphite, with over 90% of the graphite used in the US being sourced from China, exposing the industry to supply risks in the absence of diversified sources being available.

Such vulnerability can significantly impact industries such as solar energy component and EV manufacturing, he explains.

However, silicon-based anodes offer several advantages over traditional graphite, including the ability to store up to ten times more energy.

The US also relies on imports for 50% of its total demand for silicon metal, exposing the country to significant supply chain disruption.

Shifting to silicon-based batteries has the potential to reduce reliance on Chinese imports, provided that North America is successful in building a robust domestic silicon metal sector to meet regional demand.

Further, with batteries accounting for about one-third of an EV’s overall price, the use of silicon in place of graphite could also lower overall EV costs, as silicon metal is cheaper to produce, Hightower notes.

“The shift to silicon batteries is a win for consumers, EV makers and the North American economy.”

In this regard, Ferroglobe, in partnership with battery technology company Coreshell Technologies, plans to produce battery-ready metallurgical silicon for the development of low-cost, high-range EV batteries. These batteries, featuring silicon anodes, have a 30% faster charging time and 20% longer lifespan compared to traditional batteries, Hightower claims.

“[However,] the challenge is to ensure that we have a reliable, homegrown supply of silicon metal in order to accommodate this evolution,” he avers.

As part of its efforts to ensure a steady supply of silicon metal, Hightower says Ferroglobe is committed to vertical integration, including the direct ownership of raw material sources. This ensures stable operations, reliable deliveries and the ability to meet the needs of customers.

This approach enables Ferroglobe to create a transparent, dependable supply chain and maintain strong control over markets and manufacturing.

Aligned to this, Ferroglobe’s 2020-launched strategy to boost global efficiency and competitiveness, aiming to move beyond a reactive approach to market shifts and instead lead proactively, has been successful, resulting in the company being established as “the Western world’s leading merchant producer of silicon metal”, says Hightower.

Domestic Supply Challenges
It is important to establish a strong and sustainable domestic supply chain to safeguard industries critical to the US economy, Hightower emphasises.

In addition to shielding against supply chain disruptions, he asserts that building a transparent and robust silicon metal supply chain will create jobs and stimulate local economies.

While strides have been made in domestic production, more efforts are required to strengthen supply and boost capacity, he notes.

Given that silicon metal production facilities take a long time to establish, it remains critical to prioritise domestic supply chain development across North America, Hightower says.

He emphasises the need for industrial policies that encourage domestic production and shield against market disruption caused by below-cost imports, or “dumping”, as increased below-cost imports can significantly harm domestic production.

“Increased reliance in imports, as we saw during the Covid era, can result in interrupted supply chains,” he points out.

Through leveraging its global reach, partnerships and extensive history of production and innovation, Ferroglobe’s dedicated innovation group continues to explore new ways silicon metal can support domestic manufacturing.

In line with this, Hightower asserts that the company is well-positioned to meet the forecasted demand as battery technology integrates more silicon metal. In addition to its current operations, the company has plans to increase silicon metal production capacity in North America.

Ferroglobe operates four metallurgical production facilities across the US as well as three mining sites and a blending facility.

Ferroglobe, Hightower says, is committed to sustainable and innovative production methods, with its metallurgical silicon being purified to up to 99.99% without chemical reagents.