– Roshan Pujari, Founder and CEO, Stardust Power
Product
Refined lithium carbonate itself is not inherently dangerous when used properly, but like many chemicals, it can present safety risks if mishandled or improperly stored. The key risks include respiratory irritation from dust, skin and eye irritation, and reactivity with water. In industrial environments, proper safety protocols, such as the use of PPE and safe storage practices, are essential to mitigate potential hazards.
How will the refinery be laid out?
The majority of the process unit physical footprint will be just over 90 percent saltwater brine purification, bi-carbonation and carbonation, which are wet processes. The remining approximately 10 percent will be packaging and storage where the product is stored in moisture resistant, airtight super sacks.
What type of lithium will Stardust Power refine?
Stardust Power plans to refine lithium taken from lithium brines. Refining lithium from liquid brines means that open pit mining or, open evaporation ponds are not used, instead salty, lithium rich brine waters are used as a feedstock within a closed loop system. The lithium brines will be sourced from various locations across North America. Direct Lithium Extraction (DLE) techniques will be used at the extraction site, to condense the brines and remove impurities not suitable for the refinery before being transported to Muskogee. Impurities are then reinjected into the well, thus, never transported to the Muskogee site. This removes the need for evaporation ponds on the site. To extract the lithium, Stardust Power will conduct a “washing” or extraction process and the end product will deliver lithium carbonate, which is a fine, white powder.
What will be the main byproduct from the process?
The refinery will use a zero liquid discharge system that cleans and recycles the used brine water. The water is then filtered through the refinery, finally leaving the plant as steam. The main byproduct of our operations will be sodium chloride (salt) with a quality similar to road salt which may be used for commercial purposes.
Will lithium-ion batteries be produced in Muskogee?
Stardust Power does not intend to manufacture lithium-ion batteries. The Company’s focus and product line is purified lithium carbonate. The final product will be a powder-like substance that will be sent to other manufacturers who will process it into actual batteries. These batteries will then be used in electric vehicles (EVs) and other forms of energy storage. Stardust Power operates as the second stage in the supply chain for energy storage production:
DLE (Direct Lithium Extraction) —> lithium refining (by Stardust Power)
Process
At Stardust Power, sustainability is built into each step of our process. These principles guide the Company in creating long-term value for our business while being a responsible corporate citizen. Stardust Power is developing a strong North American critical material supply chain which is secure, safe, and sustainable in each aspect.
What measures will Stardust Power use to mitigate the risk of contaminating the municipal water system, groundwater, and rivers?
To ensure there is no contamination of municipal water systems, groundwater, or rivers, Stardust Power will use a zero liquid discharge system, meaning no significant water from the refining process will be released into the environment. Additionally, all areas of the plant will have concrete barriers, concrete containment barriers, and drains designed to capture any spilled brine or rainwater, which will be safely collected and reused in the plant, preventing it from coming into contact with the water system.
What air emissions will be released from the refinery? Will it contain dust emissions or toxic fumes?
The refinery will have minimal air emissions, hence our eligibility for a minor air emission permit. No dust or toxic fumes will be emitted. The production lines are designed to combine gas as well as electric power in order to minimize emissions. The refinery will be approximately 90 percent wet, hence, limited to no dust emissions. The packaging and storage area, which will be approximately 10 percent of the refinery, will have vacuum sealed automated bagging systems to capture dust.
How do you plan to power the refinery and what carbon effects will it have?
The facility will be powered by a mix of electricity from the OG&E grid and natural gas, while keeping options open for infrastructure readiness, allowing the Company to minimize air emissions and be option rich down the line as it grows. It will be supplemented by Company emergency backup generators. Stardust Power has no intention to build solar power panels or wind turbines to generate electricity for the refinery.
Safety
Stardust Power is committed to ensuring that its refining facility in Muskogee adheres to the highest standards of health, safety, and environmental compliance. The Company will develop a comprehensive plan that meets and exceeds federal, state, and local regulations. This plan will outline specific guidelines for every aspect of the operation, ensuring that all processes are conducted safely and responsibly, driven by unit specific operating procedures.
Given the nature of substances used by the company, what safety protocols will Stardust Power implement to protect workers and the surrounding community?
- Stardust Power will ensure that each aspect of its operation includes clear, detailed instructions for the safe handling of materials, thereby minimizing risks during processing and storage. The Company will provide thorough training for all employees on these safety procedures and will regularly review and update its practices to maintain a high standard of safety and regulatory compliance.
- In the handling of the finished lithium carbonate powder, Stardust Power will adhere to stringent safety standards set forth by the Occupational Safety and Health Administration (OSHA). OSHA’s guidelines ensure that workplaces remain free of hazards that could cause serious harm. These regulations cover the safe handling, storage, and use of materials such as lithium carbonate, including requirements for protective gear, ventilation systems, employee training, fire safety, and emergency response procedures. Where dry lithium is produced and packaged, non-manual automated bagging and sealing systems will be utilized.
What systems will be used to contain potential fires or smoke byproducts, both inside and outside of the facility?
- To extinguish fires involving lithium carbonate powder, Stardust Power is having an Oklahoma state-based engineering firm develop specific plant firefighting designs for both dry and wet areas. All systems developed are based on industry requirements dictated by OSHA and NFPA guidance.
- Stardust Power has designed dust collection systems to sweep the areas where dry elements of any material may be present and to capture any airborne dust from such materials, in compliance with environmental regulations in Oklahoma. Dust collection is part of the air permitting requirement and is identified in the Oklahoma Department of Environmental Quality permit. The facility will span approximately 120,000 square feet, with 9,700 square feet designated specifically for the storage of lithium carbonate powder. This storage area will be enclosed within the building and protected from weather conditions to adhere to moisture standards. Additionally, the area will be equipped with a dry chemical fire suppression system designed to quickly and safely extinguish any fires involving lithium carbonate powder. Stardust Power has designed for chemical suppression systems that work by interrupting the chemical reaction of the fire and are suitable for Class D fires, which include combustible metals like lithium in its compound forms.
- Stardust Power recognizes the importance of community collaboration during emergencies. To that end, the Company will work closely with local police, fire and rescue teams, ambulance services, and nearby hospitals to develop a Community Action Plan for responding to fires and other emergencies. Where additional equipment or specific emergency gear is needed for internal or external personnel to address fires, Stardust Power will procure and stage where practical on the property.
- To continuously enhance safety, Stardust Power employees will regularly engage with these community partners for drills, practice scenarios, training, and post-incident reviews. This collaborative approach will allow the company to learn from both drills and lessons learned, ensuring that safety procedures are updated as needed. By training together and fostering strong partnerships, Stardust Power aims to be prepared for any emergency, contributing to a safer environment for both the community and the refinery, and reinforcing its commitment as a responsible neighbor.
Community
“Together, we endeavor to create hundreds of high-quality manufacturing jobs and keep Oklahoma at the forefront of America’s energy leadership. While the site’s infrastructure and logistics are outstanding, the true asset of Oklahoma is its people,”
Where do you intend to get the labor for the refinery and how will Stardust Power support workforce development?
Stardust Power is committed to sourcing as much local talent as possible from Muskogee and the surrounding areas of Oklahoma, as well as other states when necessary. The Company has taken a proactive approach to workforce development by engaging with the Indian Capital Technology Centre, a local technical school, and universities like Oklahoma State University, which have shown a commitment to align their programs with the employment opportunities created by the business. Additionally, Stardust Power is collaborating with America Works in Muskogee to help provide job opportunities for local workers. Through the Port of Muskogee, Stardust Power, along with other manufacturers in the region, has contributed to funding scholarships for individuals interested in pursuing careers in manufacturing, further supporting the development of the local workforce.
How will Muskogee and surrounding areas vendors and individuals benefit from the refinery?
- Since selecting Muskogee, Oklahoma, as the site for its refinery in January 2024, Stardust Power has been actively engaged with the local community. The company has collaborated with leaders from surrounding churches, schools, tribal organizations, and civic groups. Stardust Power is also a member of various local and regional organizations, including the Muskogee Chamber of Commerce, the Tulsa Regional Chamber of Commerce, the Greater Muskogee Manufacturing Alliance, the Petroleum Alliance of Oklahoma, the Oklahoma State Chamber, the Oklahoma Business Roundtable, and the Tulsa Renewable Business Alliance, among others.
- Stardust Power is committed to creating hundreds of well-paying jobs that may meet and exceed the Oklahoma Quality Jobs program requirements, offering wages at least 110% of the average wage for Muskogee County. The construction and operation of the refinery are expected to have a positive economic impact on local businesses, including restaurants, shops, and other service providers. Additionally, Stardust Power has demonstrated its commitment to supporting local education by partnering with schools and educational institutions to provide curriculum alignment and scholarship opportunities for individuals interested in pursuing careers in manufacturing.
Miscellaneous
Who is Stardust Power’s end customer and what would we sell?
We intend to sell our end product, a battery grade lithium carbonate, to US focused customers that will use the lithium to strengthen US supply chains, enable US energy leadership and advance US manufacturing. These could be OEM’s, vehicle manufacturers, battery makers or cathode active material (CAM) producers.
How does Stardust Power benefit America?
The U.S. is highly dependent on foreign countries, primarily China, for producing battery-grade lithium used in advanced EV batteries and other lithium–ion products, putting our country at significant risk of supply disruptions, price volatility and trade wars. By bringing this part of the supply chain back to the US, Stardust Power is addressing a major vulnerability and national security risk, as well as returning manufacturing and jobs to Oklahoma.
Is Stardust Power going to compete with Oklahoma’s oil and gas industry?
No. Stardust Power’s refinery will complement, expand and support Oklahoma’s oil and gas industry. Part of the reason we chose Oklahoma was precisely because the state is blessed with exceptional energy workers, who have the technical knowledge and understanding of both working in local communities and the importance of safety. As a new private-sector employer, Stardust Power expects to create hundreds of new jobs in Oklahoma.
Is the Stardust Power refinery in line with the current Presidential energy policy?
Yes, in President Trump’s Executive Order “Unleashing American Energy” signed January 20, 2025, it repeatedly sites the need for domestic mining and processing of critical and non-fuel minerals, which includes lithium. The President plans to restore US mineral dominance by “establishing our position as the leading producer and processor of non-fuel minerals, including rare earth minerals, which will create jobs and prosperity at home, strengthen supply chains for the United States and its allies, and reduce the global influence of malign and adversarial states.”