The production of nickel cathodes at the Sandouville nickel refinery has ceased. The last nickel matte delivery was received in early January 2025 with the remaining inventory processed in Q1 2025. A pre-feasibility study (PFS) to assess the potential conversion of the Sandouville plant to produce pCAM (the GalliCam project) is underway.
GalliCam project
Sibanye-Stillwater’s GalliCam project aims to produce precursor Cathode Active Material (pCAM), to advance the European and French EV battery industry by repurposing Sibanye-Stillwater’s Sandouville nickel refinery from its previous product mix of nickel (Ni) metals and salts into one of Europe’s first pCAM producers, with an initial capacity of up to 10,000 tonnes per annum of contained Ni.
The Sandouville industrial zone is close to the developing French “Battery Valley”, and the Sandouville nickel refinery is a fully permitted high-level Seveso site, with the relevant expertise and track record for processing chemicals. The French electric grid contains a high degree of non-fossil energy, supporting the establishment of a supply chain with low carbon emissions towards a net-zero goal.
A scoping study, finalised in February 2024, indicated a promising opportunity to convert the existing Sandouville nickel refinery to produce high-quality nickel-bearing pCAM with a low environmental impact.
A pre-feasibility study was initiated in March 2024. The pre-feasibility study aims to confirm the effectiveness of the innovative process, outline the ideal configuration, and refine capital and operating costs. A positive pre-feasibility outcome will allow a definitive feasibility study of the alteration of the refinery to commence.
The process, a proprietary intellectual property of Sibanye-Stillwater, uses a chloride medium that has a number of potential advantages compared to the conventional pCAM manufacturing process. The process is expected to reduce energy consumption and yield a lower carbon footprint, decrease the use of external reagents and therefore reduce costs. Additionally, effluent waste will be lower. By re-using part of the current infrastructure of the Sandouville refinery, both the capital expenditure and lead times should be reduced compared to a greenfield project. The possibility of using recycled battery material as feed is included in the study.
The purpose of the GalliCam project is to advance Sibanye-Stillwater’s strategy into the battery space in the European market. It will contribute to the objective of the EU Critical Raw Materials Act, of having 40% refining capacity and 15% recycling of internal demand on European soil. Sibanye-Stillwater is aiming to become a key player in serving Europe’s battery chemicals needs – in addition to the GalliCam project, Sibanye-Stillwater’s Keliber lithium project in Finland is expected to be the first European integrated producer of lithium-hydroxide, also a component of CAM.
The European Commission has recognised the strategic significance of the GalliCam project by granting it Strategic Project status under the EU’s Critical Raw Materials Act. The project has also been selected for a grant by the EU Innovation Fund, and the agreement was signed on 26 February 2025.
The GalliCam process is still under development, and Sibanye-Stillwater is working with partners towards a successful outcome. Further announcements will be made once the final stages of the study are completed before the end of 2025. The planned completion of the pre-feasibility study was changed from the original Q1 2025 to Q4 2025 due to changes in the project scope.
