WORCESTER—In a major advancement for sustainable energy technology, researchers at Worcester Polytechnic Institute have developed a scalable new method to recycle lithium-ion batteries, offering significant environmental and performance benefits over conventional techniques.
The work, led by Professor Yan Wang, William B. Smith Professor of Mechanical and Materials Engineering at WPI, was recently published in the peer-reviewed journal “Energy Storage Materials.” The study outlines a hydrometallurgical upcycling process that recovers over 92% of critical metals—including nickel, cobalt, and manganese—from spent nickel-lean (Ni-lean) cathodes commonly found in used batteries.
According to the announcement, the new method not only improves recovery rates but also transforms the salvaged materials into high-performance cathode powders suitable for reuse in commercial batteries. Testing showed that recycled batteries retained 88% capacity after 500 charge cycles and more than 85% after 900 cycles, results comparable to those made with virgin materials.
In addition to performance gains, the process offers environmental advantages. The team reports it consumes 8.6% less energy than standard hydrometallurgical recycling and reduces carbon emissions by nearly 14%—slightly more than with existing direct upcycling methods.
“This work not only addresses the environmental challenges of battery waste but also helps reduce our dependence on mining for critical materials,” Wang said in a statement. “We’ve shown that it’s possible to create high-performance batteries from recycled materials at scale, which is essential for building a more sustainable and resilient battery supply chain.”
The innovation arrives as pressure mounts on industries and governments to create circular solutions for battery waste and reduce reliance on mining for electric vehicles and other clean energy technologies. WPI’s breakthrough could prove a key component in building a more climate-conscious battery economy.
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