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Cornish Lithium Drives Sustainability at UK Plant

PlantPAx distributed control system helps mineral company prove novel mica processing approach can extract battery metal from Cornish granite rock.

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Cornish Lithium plant

Cornish Lithium is a pioneering mineral exploration and development company supporting the UK’s green revolution and the transition to renewable energy by building a secure domestic supply of lithium for electric vehicles and power storage batteries.

The company is using highly innovative and sustainable processes to extract lithium from both geothermal waters and hard rock in the historic mining district of Cornwall, UK. Cornish Lithium aims to provide the foundation for a modern-day renaissance of Cornwall’s 4,000-year mining heritage by extracting metals that are needed for modern technologies such as electric vehicles and renewable energy.

Jeremy Wrathall
Jeremy Wrathall
Founder and CEO, Cornish Lithium
Challenge
  • Wanted process control with little maintenance and training overhead
  • Needed installation and changes to have low impact on operations
  • Sought systems that could scale easily with production
Solution
  • PlantPAx® distributed control system to manage industrial processes and energy systems
  • Allen‑Bradley® ControlLogix® controllers
  • FactoryTalk® View Site Edition interface
Result
  • Helped validate viability of novel Lepidico lithium refining process
  • Contributed to highly sustainable lithium processing in UK
  • Created showcase plant for European lithium operations

Challenge

Lithium is key to the adoption of sustainable energy systems, representing one of the main ingredients in electric vehicle and grid-scale batteries.

However, lithium production is highly concentrated, with almost 78% of supplies coming from just three countries in 2024. As nations such as the UK look to develop their own clean energy supply chains, they are seeking to find and exploit local sources of lithium.

Aiming to address this challenge is Cornish Lithium, a pioneering mineral exploration and development company looking to support the UK’s and transition to renewable energy by building a secure domestic supply of lithium for electric vehicles and power storage batteries.

Cornish Lithium plans to extract lithium from granite rock in a repurposed former china clay pit at Trelavour Downs in Cornwall, UK, with a goal of producing around 10,000 tonnes a year of battery-grade lithium hydroxide.

The company chose to adopt a novel processing technique to produce a refined, battery grade product on site in Cornwall. To do this, it was necessary to build an industrial-scale demonstration plant based on technology originally patented by Australian company Lepidico. Cornish Lithium has now acquired the patents and IP and rebranded it as Li-Stract, given that the process has potential to be used at other lithium deposits worldwide.

Unlike traditional processing, which requires high temperatures and pressures, the Lepidico process can extract lithium from a range of deposits at relatively low temperatures and atmospheric pressure. This could reduce process-related greenhouse gas emissions by around 25%.

For the demonstration plant to be a success, the company required a distributed control system that could be installed with little impact on operations, would require little maintenance and training, and scale easily to support industrial operations. This system would enable accurate monitoring of the system and allow feedback for improvements to be made.

Solution

“We did a comprehensive review of the people who might work with us on this and found that Rockwell Automation was the best option,” said Jeremy Wrathall, Cornish Lithium’s founder and CEO.

“Rockwell was prepared to work with us on something that is very new - and we greatly value the fact that Rockwell is a globally respected brand we could trust not just for the demonstration plant but to walk with us as we move towards the full-scale solution.”

Cornish Lithium selected a Rockwell Automation PlantPAx® distributed control system to manage both the industrial processes and the energy systems at the Cornish demo plant, and also installed Allen‑Bradley® ControlLogix® controllers and a FactoryTalk® View Site Edition interface.

“We built, with Rockwell’s help on the instrumentation and control side, a very large and semi-industrial scale demonstration plant that mimics exactly what the full-scale production plant will look like and the way it will behave,” said Wrathall.

“Rockwell is firmly integrated into that process and enables us to control what is going on very effectively."

“The demonstration plant is like a giant chemistry set, but it is vital that we have the controls and feedback that Rockwell has enabled with their cutting-edge technology and monitoring system.”

As Cornish Lithium was putting the finishing touches to its demonstration plant, there was an unexpected development. Lepidico went into administration and the intellectual property and patents for its lithium mica processing technologies were put up for sale.

Cornish Lithium acquired the patents and IP and has now rebranded the processing technology as Li-Stract. The Trelavour Downs Demonstration Plant is the only site in the world to extract lithium using the Li-Stract process, which Wrathall considers to be “probably one of the most low-carbon processes we’ve seen”.

The Li-Stract process is not just important from a sustainability perspective. It also allows lithium to be extracted and refined at source, without having to export the material for processing abroad. This is a big deal because lithium refining capacity is even more concentrated than production.

China accounts for approximately 80% of global refining, with Argentina and Chile representing a further 15%.

Result

With Rockwell Automation technology helping optimize production and empowering operators with a single pane of glass for process and energy control, Cornish Lithium has been able to prove the Li-Stract process works.

In doing so, it has become the first company to produce lithium hydroxide mined and refined in the UK. It wasn’t all plain sailing, said Wrathall. “That’s why it was good to be working with Rockwell,” he said. “We built the demonstration plant to break it, and we broke it several times. But we then made many improvements, which we will take forward as we start construction of the full-scale production plant.”

“We re-engineered it together with Rockwell every step of the way.”

The experience has given Cornish Lithium the confidence to press ahead with large-scale, sustainable, home-grown lithium extraction and processing the in UK.

Investors have also been impressed, with Cornish Lithium securing £35 million ($47 million) of equity funding in September 2025.

Furthermore, said Wrathall, “This project has been designated by the UK government as nationally significant, a designation that’s usually reserved for nuclear power stations, airports and major infrastructure.”

It is not just the British administration that is taking an interest in the scheme, he added.

“There are other deposits in Europe, nearly all of the same mineral type, so we wanted to build a physical demonstration plant to show we can take other people’s lithium-bearing minerals and process them,” he said. “This instrumentation and control mechanism has allowed us to optimize the system.

“It’s been a huge advantage to be working with Rockwell on this.”

Published May 21, 2026

Topics: Optimize Production Empower People Drive Sustainability Metals Mining
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