New Jersey Startup Reduces Copper Costs with Innovative Technology

Copper Demand and a Novel Extraction Solution

A significant surge in demand for copper is anticipated to drive prices to unprecedented levels. The global shift away from fossil fuels necessitates a doubling of copper production in the coming years, exceeding all historically mined quantities.

Still Bright's Innovative Approach

Still Bright, a New Jersey-based startup established in 2022, believes it has discovered a groundbreaking and environmentally friendly method to reduce these costs.

Randy Allen, co-founder and CEO of Still Bright, explained to TechCrunch that the depletion of easily accessible copper deposits and the need for numerous new mines – potentially over 60 annually – presents a considerable challenge.

However, a substantial portion of this demand could be addressed by enhancing copper recovery from existing ores.

Enhanced Copper Extraction Technology

Still Bright has engineered a new copper extraction process capable of recovering almost all of the copper from standard ores, eliminating pre-processing steps that typically result in a 20% metal loss.

This technology is effective enough to even process tailings – the discarded materials from mines that still contain residual copper.

According to Allen, the company can reclaim copper previously considered waste.

Securing Funding for Expansion

To scale production from single-digit to hundreds of tons per year, Still Bright has secured an $18.7 million seed round. The investment was led by Material Impact and Breakthrough Energy Ventures, with participation from Azolla Ventures, Fortescue, Impact Science Ventures, and SOSV.

A Cleaner Extraction Process

Still Bright’s technology enables copper extraction without generating harmful pollutants.

Unlike conventional methods that involve burning away unwanted ore components and releasing emissions, Still Bright utilizes a vanadium-based solution to extract copper from ores.

The spent vanadium solution is then regenerated using electricity.

Inspired by Vanadium Flow Batteries

The core technology draws inspiration from long-duration energy storage systems known as “vanadium flow batteries.” These batteries employ a vanadium-based solution stored in tanks, charged and discharged by flowing it across a membrane.

Allen noted that the development was somewhat serendipitous, stemming from the work of the company’s CTO, Jon Vardner, on both vanadium flow batteries and vanadium-based copper extraction.

Modular and Cost-Effective System

Still Bright’s modular system is designed for installation at mines of varying sizes.

The rapid nature of the vanadium-based process allows for significantly smaller equipment compared to traditional refineries for equivalent copper production.

The processing time is measured in minutes to an hour, enabling a compact system.

This smaller footprint translates into financial benefits, with Allen stating that Still Bright’s equipment is 70% to 90% cheaper than conventional pyrometallurgical equipment.

While current operating costs are comparable to typical refineries, Allen anticipates further cost reductions.

Future Plans and Commercialization

Still Bright plans to construct a demonstration unit capable of producing 500 tons of copper annually in 2027 or 2028.

This represents a substantial increase from the current pilot-scale unit, which produces 2 tons per year.

The ultimate goal is a commercial-scale system with an annual output of 10,000 tons.

Strategic Timing and Potential Tariffs

The company aims to begin refining copper in sufficient quantities to capitalize on potential tariffs imposed by President Trump on metal imports.

The resulting revenue would be used to fund the development and deployment of commercial-scale units.

Allen believes Still Bright is positioned to become one of the most cost-competitive copper producers.

(Note: This article has been updated to reflect the correct investor name – Azolla Ventures, not Apollo Ventures.)