Two-step flash-heating cuts battery recycling chemicals by 95%

Rice University researchers have developed a novel two-step flash Joule heating chlorination and oxidation (FJH ClO) process for recycling lithium-ion batteries that significantly reduces chemical use and energy consumption. This acid-free method rapidly extracts lithium, cobalt, and graphite from spent batteries with high purity by first exposing battery waste to chlorine gas to break down materials, then heating in air to form metal oxides that separate from lithium chloride, which dissolves easily in water. Compared to conventional recycling methods that rely on strong acids, long reaction times, and generate wastewater, the FJH ClO process uses about half the energy and up to 95% fewer chemicals, offering a cleaner, faster, and more environmentally friendly alternative. The technique enables full-spectrum recovery of critical battery materials in a streamlined, single-route process, avoiding multiple chemical treatments common in existing methods. This efficiency not only promises economic benefits through lower operating costs and faster turnaround but also helps reduce reliance on new mining, mitigating environmental impact. The research