Articles tagged with "battery-recycling"
Redwood attracts Google for its $425M Series E as AI power needs rise
Redwood Materials, a battery recycling and cathode production startup founded by former Tesla CTO JB Straubel, has raised $425 million in its Series E funding round, attracting new investors including Google alongside existing backers like Nvidia’s NVentures, Capricorn, and Goldman Sachs. This round, led by venture firm Eclipse, has pushed Redwood’s total capital raised to $4.9 billion and reportedly values the company at over $6 billion. The fresh capital is fueling Redwood’s expansion into energy storage solutions aimed at powering AI data centers and large industrial sites, a strategic pivot reflecting the surging electricity demand driven by AI, manufacturing, and electrification. Originally focused on creating a circular supply chain by recycling battery scrap from electronics and extracting key materials like nickel and lithium, Redwood has broadened its operations to include cathode production and a new business line called Redwood Energy. This venture repurposes used EV batteries into micro-grids to supply power for data centers, leveraging the company’s extensive inventory—over
energybattery-recyclingenergy-storageAI-data-centerselectric-vehiclesmaterials-recoverygrid-scale-storageBMW's mechanical recycling keeps battery materials in active use
BMW Group has inaugurated the Cell Recycling Competence Centre (CRCC) in Salching, Germany, a facility dedicated to mechanical direct recycling of battery cells and production scrap. Unlike conventional battery recycling methods that rely on energy-intensive chemical or thermal processes, BMW’s approach preserves active battery materials in a largely intact state, enabling their direct reuse in new battery cell manufacturing. The CRCC primarily processes unused cells and pilot production residues, which are more uniform than end-of-life batteries, facilitating a short-loop recycling system that reduces energy consumption, material losses, and dependence on newly mined raw materials. The recovered materials are sent to BMW’s Cell Manufacturing Competence Centre in Parsdorf, effectively closing the loop between production and recycling. This initiative is part of BMW’s broader 4Re strategy—rethink, reduce, reuse, and recycle—and is integrated into its industrial battery production rather than functioning as a standalone recycling operation. The CRCC, operated by Encory (a joint venture between BMW and Interzero Group),
energybattery-recyclingmechanical-recyclingmaterials-recoverycircular-economyBMWsustainable-manufacturingChina’s method recovers 95% lithium from dead batteries using CO2, water
Chinese researchers from the Chinese Academy of Sciences and Beijing Institute of Technology have developed a novel, environmentally friendly method to recover over 95% of lithium from spent lithium-ion batteries using a combination of carbon dioxide (CO₂) and water. This process leverages carbonic acid formed by CO₂ reacting with water, which gently dissolves lithium from battery cathodes at room temperature and normal pressure, avoiding the harsh acids, high temperatures, and toxic chemicals typical of traditional recycling methods. Besides efficient lithium recovery, the method also upcycles other cathode metals like cobalt, nickel, and manganese into reusable catalysts, while permanently sequestering CO₂ in solid by-products, thus providing both lithium reclamation and carbon capture benefits. The new “three-in-one” process is safer, cheaper, and easier to scale than conventional techniques, minimizing environmental impact by eliminating the need for grinding aids or additional leaching agents. However, while the method has been successfully demonstrated in the lab, its industrial-scale feasibility remains unpro
energylithium-recoverybattery-recyclingcarbon-captureclean-energymaterials-upcyclingsustainable-technologyThe 22 top clean tech and energy startups from Disrupt Startup Battlefield
The article highlights 22 leading clean tech and energy startups selected from TechCrunch’s annual Startup Battlefield pitch contest, which narrows thousands of applicants to 200 top contenders across various categories. These startups showcase innovative technologies aimed at sustainability and energy efficiency. Notable examples include AraBat, which uses a bio-based recycling process to recover critical metals from spent lithium-ion batteries using plant waste instead of toxic chemicals, and Aruna Revolution, which produces compostable menstrual pads from agricultural by-products, eliminating plastics and harmful substances. Other standout companies include CarbonBridge, which develops bioreactors for microbial gas fermentation to convert waste gases like methane and CO₂ into valuable molecules more efficiently than traditional methods, and Carbon Negative Solutions, which uses AI to transform industrial waste into carbon-negative cement compatible with existing equipment. Additionally, COI Energy operates a marketplace for enterprises to trade excess energy capacity, optimizing grid usage, while Coral offers an AI and blockchain-powered platform for automated carbon accounting and credit tracking. The startups collectively represent cutting-edge
energyclean-technologybattery-recyclingAI-energy-managementelectric-vehicle-chargingultracapacitorscarbon-negative-materialsBMW launches new recycling facility to reuse EV battery materials
BMW has inaugurated its new Cell Recycling Competence Center (CRCC) in Salching, Lower Bavaria, developed in partnership with Encory GmbH. The facility focuses on an innovative direct recycling process for electric vehicle (EV) battery cells, aiming to recover residual materials from battery production scrap and return valuable raw materials directly to manufacturing. Unlike traditional energy-intensive chemical or thermal recycling methods, BMW’s approach uses mechanical dismantling to reuse materials without breaking them down into elemental components, thereby saving energy and reducing emissions. The CRCC occupies around 2,100 m² and is operated by Encory, a joint venture equally owned by BMW Group and the Interzero Group. The center emphasizes regional collaboration, with most contractors based in Germany near Salching to minimize transport distances and support local industry. The recycling center complements BMW’s broader battery cell ecosystem in Bavaria, which includes development and pilot production sites in Munich and Parsdorf. Surplus materials from pilot production are sent to the CRCC for recycling, enabling a
energymaterialselectric-vehiclesbattery-recyclingsustainabilityBMWrenewable-energyLithium recovered from battery waste using electrochemically driven low-cost process
Researchers at the University of Illinois Urbana-Champaign have developed a novel, electrochemically driven process to recover lithium from spent lithium-ion batteries (LIBs), addressing critical supply chain concerns for this essential battery metal. Their method involves leaching metals from dismantled batteries into an organic solvent, then selectively capturing lithium ions using a polymer-coated electrode within an electrochemical cell. The key innovation is a redox-active crown ether copolymer that selectively binds lithium even in the presence of competing metals like iron, nickel, and cobalt. This polymer can be electrochemically regenerated by applying a voltage, releasing the captured lithium for collection while leaving other metals behind, enabling repeated, efficient recovery cycles without the need for harsh chemical treatments. The study, published in ACS Energy Letters, highlights that this approach is both highly selective and energy-efficient, with lithium uptake doubled due to the redox-active polymer design. A techno-economic analysis suggests the recovered lithium could be produced at costs competitive with or lower than current market prices (
lithium-recoverybattery-recyclingelectrochemical-processlithium-ion-batteriessustainable-materialsenergy-storagecopolymer-technologyRedwood Materials reportedly cuts 5% of staff after $350M raise
Redwood Materials, a Nevada-based battery recycler and cathode producer founded in 2017 by former Tesla CTO JB Straubel, has reportedly cut about 5% of its workforce—roughly a few dozen employees out of 1,200—shortly after raising $350 million in a Series E funding round. The company specializes in recycling materials such as cobalt, nickel, and lithium from battery scrap and used EV batteries, which it then sells back to customers including Panasonic. Redwood has also expanded into cathode production and recently launched a business repurposing old EV batteries for energy storage, a sector benefiting from the rise of AI data centers. The October funding round increased Redwood’s valuation to approximately $6 billion. Despite the recent capital infusion, the company opted for workforce reductions, though a spokesperson declined to comment on the layoffs. As of June, Redwood had accumulated over 1 gigawatt-hour of batteries for its energy storage initiatives, signaling ongoing investment in this growing market segment.
energybattery-recyclinglithium-ion-batteriescathode-productionenergy-storageelectric-vehiclesmaterials-recyclingTwo-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
battery-recyclinglithium-ion-batteriesenergy-efficiencymaterials-recoverysustainable-technologylithium-extractionclean-energyHow much of the AI data center boom will be powered by renewable energy?
The article discusses the rapid growth of AI data centers and their significant power demands, highlighting that global spending on data centers is projected to reach $580 billion this year—surpassing investments in new oil exploration by $40 billion. This shift underscores the evolving global economy and raises concerns about the strain on electrical grids, especially as many data centers are planned near large urban populations. The majority of electricity demand from these centers is expected to come from the U.S., with China and Europe also contributing substantially. The article emphasizes that renewable energy adoption will likely be driven more by business considerations than environmental policies. A key potential positive noted is the opportunity for innovation in renewable energy and data center design, with companies like Redwood Materials launching initiatives such as Redwood Energy to create microgrids powered by repurposed EV batteries specifically for AI data centers. This approach could help mitigate grid stress, particularly in regions prone to power shortages like Texas. However, questions remain about how many planned data centers will actually be built given the enormous
energyrenewable-energydata-centersAI-data-centerselectrical-gridsmicrogridsbattery-recyclingSwiss researchers pioneer robot-assisted recycling for EV lithium-ion batteries
Swiss researchers, led by the Bern University of Applied Sciences (BFH) under the CircuBAT project, have developed a pioneering robotic system to enhance the sustainable second life and recycling of electric vehicle (EV) lithium-ion batteries. This innovation aims to close the loop between battery production, use, and recycling by automating the dismantling, sorting, and upcycling processes, which have traditionally been labor-intensive and hazardous. The system, designed at the Swiss Battery Technology Center (SBTC), uses precision robotics to safely separate battery modules and recover high-quality raw materials with minimal manual handling, thereby improving recycling efficiency and reducing environmental impact. In addition to recycling, the project introduced a “Battery Expert System” that analyzes aging patterns of thousands of cells to identify those suitable for repair or repurposing, enabling retired EV batteries to be reused as stationary energy storage systems for buildings or renewable energy grids. The researchers also developed automated dismantling methods, direct material recovery techniques, and novel electrode coatings that lower energy consumption
roboticselectric-vehicleslithium-ion-batteriesbattery-recyclingsustainable-energyautomated-dismantlingcircular-economyNew recycling tech recovers nearly pure nickel and cobalt from old EV batteries
Researchers at South Korea’s Ulsan National Institute of Science and Technology (UNIST) have developed an innovative, eco-friendly recycling process that recovers over 95% of nickel and cobalt from used electric vehicle (EV) batteries with near-perfect purity. Unlike conventional wet recycling methods that rely on strong acids and multi-step chemical treatments, this new technique uses a selective electrochemical separation facilitated by a deep eutectic solvent (DES) called ethaline, composed of ethylene glycol and chloride ions. This solvent selectively binds nickel and cobalt ions, enabling their efficient separation through distinct reduction voltages, thereby overcoming the typical trade-off between purity and recovery rate. The process achieves a nickel-cobalt separation factor greater than 3,000 and recovers more than 97% nickel from synthetic mixtures, with real battery leachates yielding 99.1% nickel purity and 98.8% cobalt purity at recovery rates above 95%. Additionally, the method’s electrodeposition step naturally generates chlorine within
battery-recyclinglithium-ion-batteriesnickel-recoverycobalt-recoveryelectrochemical-separationsustainable-materialsdeep-eutectic-solventYouTuber builds off-grid power wall from 500 used vape batteries
British engineer and YouTuber Chris Doel created a 2.52 kWh off-grid power wall using 500 recycled lithium-ion batteries salvaged from disposable vape pens. By collecting discarded vapes, testing each battery for viability, and assembling them into 56 modules with 3D-printed holders, Doel constructed a system that delivers about 50 volts DC. This power wall, connected to an inverter, converts the energy to standard 230 volts AC, enabling him to run his workshop appliances such as a kettle, microwave, fan, and computer without relying on the electrical grid. Doel’s project not only showcases a practical reuse of electronic waste but also highlights the environmental impact of disposable vapes, which often end up in landfills despite containing rechargeable batteries. His setup, weighing around 38 kilograms and valued at approximately £2,500 if built with new batteries, was assembled using mostly reclaimed materials and repurposed components like a scooter battery management system. Beyond powering his workshop,
energybattery-recyclinglithium-ion-batteriesoff-grid-powerrenewable-energysustainable-technologyDIY-energy-storageChina restores 76% capacity in used EV batteries with molten salt
Researchers at Huazhong University of Science and Technology have developed a novel molten salt-based method to restore degraded lithium-ion battery cathodes, specifically targeting NCM811 (LiNi₀.₈Co₀.₁Mn₀.₁O₂), a common material in electric vehicle (EV) batteries. Unlike traditional recycling techniques that extract metals but destroy the cathode’s atomic structure, this approach uses a ternary molten salt mixture (lithium hydroxide, lithium nitrate, and lithium salicylate) to repair defects and replenish lost lithium ions. The process restores the cathode’s original crystal structure and performance, achieving an initial discharge capacity of 196 mAh/g and retaining 76% capacity after 200 cycles, outperforming most current recycling methods. The molten salt method operates at lower temperatures without harsh chemicals, reducing energy consumption and environmental impact. This technique effectively heals both internal and surface damage, removing unwanted layers and reviving the ordered layered structure critical for
energybattery-recyclingelectric-vehicleslithium-ion-batteriesmolten-saltcathode-restorationsustainable-materialsJB Straubel's Bet On EV Battery Recycling Is Paying Off, Bigly
Redwood Materials, an EV battery recycling startup founded in 2017 by Tesla co-founder J.B. Straubel, has recently secured over $350 million in Series E funding despite a downturn in the US EV market following the expiration of the $7,500 federal tax credit. This strong investor interest is attributed to Redwood’s strategic expansion beyond EV battery recycling into the rapidly growing battery energy storage system (BESS) market. The company aims to create a domestic circular supply chain for critical minerals and has positioned itself as a key player in the broader electricity ecosystem. The investment round was led by California venture capital firm Eclipse, whose board member Joe Faith highlighted Redwood’s innovative approach and diversification strategy. Faith also emphasized the importance of expanding renewable energy resources and infrastructure in the US, countering political support for fossil fuels. The article notes that renewable energy sources like solar and energy storage accounted for 82% of new power generation capacity added to the US grid in the first half of the year, underscoring
energybattery-recyclingelectric-vehiclesenergy-storagerenewable-energymaterialsEV-batteriesTurning waste to power: Nissan and Lithion redefine EV battery recycling in Canada
Nissan Canada has partnered with Montreal-based clean tech company Lithion Technologies to launch an advanced EV battery recycling initiative aimed at recovering and repurposing valuable materials from end-of-life electric vehicle batteries. Lithion’s patented hydrometallurgical process uses a water-based, closed-loop system to efficiently extract up to 95% of battery materials and 98% of critical minerals such as lithium, nickel, cobalt, and graphite. This method contrasts with traditional pyrometallurgical techniques by significantly reducing greenhouse gas emissions and battery waste, thereby supporting a more sustainable and circular economy for EV batteries. The initiative leverages Lithion’s commercial recycling facility in Saint-Bruno, Quebec, and builds on Lithion’s prior collaboration with Hyundai Auto Canada. By localizing battery recycling, Nissan aims to reduce dependence on raw material mining, lower production emissions, and strengthen Canada’s clean technology sector. This partnership aligns with Nissan’s broader sustainability goals to close the loop on battery use, responsibly manage end-of-life batteries
energymaterialselectric-vehiclesbattery-recyclinglithium-ion-batteriesclean-technologysustainabilityUsed EV batteries can be turned into fertilizers with this new method
Researchers at the University of Wisconsin-Milwaukee, led by Professor Deyang Qu, have developed a novel method to recycle used lithium iron phosphate (LFP) electric vehicle (EV) batteries into fertilizers. This process employs an ion-exchange technique to recover lithium by replacing it with potassium, leaving behind key fertilizer components such as phosphorus, potassium, and nitrogen. The innovation addresses the growing challenge of EV battery waste, particularly as conventional recycling is costly and yields limited value beyond lithium recovery. By converting battery materials into fertilizers, the method not only reduces environmental waste but also supports agriculture, offering a potentially sustainable economic solution. The research, supported by UWM and the USDA Agricultural Research Service, aims to scale up fertilizer production for field testing, including planned trials on tomato crops. This approach could create a domestic supply of essential fertilizer minerals, currently mostly imported, while reducing the energy footprint associated with mining and transportation. The method is particularly relevant given the expected surge in expired lithium-ion batteries after about a decade
energybattery-recyclinglithium-ion-batterieselectric-vehiclessustainable-agriculturefertilizer-productionwaste-managementNew battery waste-eating bacteria offers self-sufficient recycling
Researchers at Boston College have identified a bacterium, Acidithiobacillus ferrooxidans (Atf), capable of consuming materials found in spent batteries, particularly iron and stainless steel, to facilitate recycling. This bacterium thrives in acidic environments and can use battery casing materials as a food source, producing solutions effective for leaching cathode materials. Notably, Atf can grow without sulfate, a toxic additive commonly used in bacterial cultures, which could eliminate the need to transport hazardous chemicals during recycling. The discovery that stainless steel, a complex alloy commonly found in batteries, supports bacterial growth even better than pure iron was an unexpected and significant finding. The study addresses the growing environmental and safety challenges posed by the increasing volume of battery waste and the energy-intensive nature of traditional recycling methods. By leveraging Atf’s natural abilities, the researchers aim to develop a self-sufficient, safer, and more sustainable recycling process that reduces reliance on toxic chemicals and high-energy industrial techniques. The team is currently working on evolving
battery-recyclingAcidithiobacillus-ferrooxidanssustainable-materialsenergy-efficient-recyclingbattery-waste-managementcathode-material-recoveryenvironmental-technologyRedwood Materials raises another $350M to power up its energy storage business
Redwood Materials, a battery recycling and cathode production company founded by former Tesla CTO JB Straubel, has raised $350 million in a Series E funding round led by Eclipse, with strategic investment from Nvidia’s NVentures. The company’s valuation is estimated at around $6 billion, up $1 billion from its previous valuation. The new capital will be used to expand Redwood’s energy storage business, increase refining and materials production capacity, and hire additional engineering and operations staff. Originally focused on creating a circular supply chain by recycling battery scrap and consumer electronics to extract valuable materials like cobalt, nickel, and lithium, Redwood supplies these materials to major customers such as Panasonic, GM, and Toyota. Recently, the company launched Redwood Energy, which repurposes retired EV batteries—those with remaining life unsuitable for recycling—into large-scale energy storage systems. These systems, powered by renewable sources like wind and solar, are designed primarily to serve AI data centers and industrial sites, with potential grid integration and compatibility
energybattery-recyclingenergy-storageEV-batteriesrenewable-energygrid-scale-storagematerials-recoveryChina achieves 99.6% recovery of materials from retired EV batteries
China has made significant progress in electric vehicle (EV) battery recycling, achieving a 99.6% recovery rate for key materials such as nickel, cobalt, and manganese, with lithium recovery reaching 96.5%. This success follows the implementation of new national standards for dismantling, testing, and recycling retired EV batteries, now totaling 22 regulations. These standards, widely adopted across the industry, promote environmental sustainability and economic circularity by enabling efficient material recovery and reuse. For example, facilities like the Battery Science & Technology workshop in Tianjin employ processes including dismantling, crushing, and purification to recover over 95% of lithium for new battery production. China is also strengthening its leadership in global battery recycling standards by establishing a national technical committee that includes experts from all stages of the battery lifecycle. This committee, led by the General Administration of Market Supervision and the Ministry of Industry and Information Technology, aims to unify standards for batteries used in vehicles, ships, and energy storage systems. Chinese experts
energyelectric-vehiclesbattery-recyclingmaterials-recoverysustainabilitylithium-batteriescircular-economyNew method uses batteries' own energy to recover 95% of key metals
Researchers have developed an innovative battery recycling method that harnesses a spent lithium-ion battery’s own stored chemical energy to recover key metals with high efficiency. By recharging the battery to a controlled level (around 70% capacity), they trigger a self-heating thermal runaway reaction that raises the internal temperature to about 1,100°C. This heat breaks down complex cathode materials, such as nickel manganese cobalt oxide (NMC), into simpler metallic or oxide forms, facilitating easier extraction without the need for extensive external energy or harsh chemicals. The process involves a two-stage material recovery: first, washing the thermally treated powder with water to remove soluble lithium salts (recovering over 60% lithium), and second, using dilute hydrochloric acid to dissolve remaining lithium and transition metals, achieving over 93% lithium and 95% transition metal recovery in tested cells. This method contrasts with conventional recycling techniques like pyrometallurgy and hydrometallurgy, which require high energy input or large
energybattery-recyclinglithium-ion-batteriesthermal-runawaymetal-recoverysustainable-energymaterials-scienceA Reversible Self-Assembling Solid-State Battery Electrolyte From MIT - CleanTechnica
Researchers at MIT have developed a novel self-assembling solid-state battery electrolyte that addresses key challenges in battery recyclability and sustainability. Published in a 2025 journal study, this electrolyte is made from aramid amphiphiles—molecules that self-assemble into nanoribbons through reversible, non-covalent bonds like hydrogen bonding and π–π stacking. These nanoribbons form a stable, high-performance solid electrolyte with good conductivity and mechanical strength. Crucially, the electrolyte can be fully disassembled by immersing used battery cells in a simple organic solvent, allowing the battery components to revert to their original molecular forms for easy, non-toxic recycling. This breakthrough contrasts with conventional lithium-ion batteries, which often prioritize performance over recyclability and result in complex, difficult-to-recycle waste. The MIT approach integrates recyclable chemistry from the outset, potentially enabling a circular lifecycle for solid-state batteries. While still in early stages, this innovation could significantly improve the sustainability of electric vehicle batteries by simplifying material recovery
energysolid-state-batterybattery-recyclingelectrolytematerials-sciencelithium-ion-batterysustainable-energyUK's first recycled EV battery cells cut carbon emissions by 32%
Altilium and Jaguar Land Rover (JLR) have unveiled the UK’s first electric vehicle (EV) battery cells made using recycled cathode and anode materials, showcased at Cenex Expo 2025. These automotive-grade NMC 811 multilayer pouch cells incorporate cathode active material (CAM) recovered from end-of-life EV batteries via Altilium’s EcoCathode process, achieving recycled content levels that meet EU 2036 targets. Initial tests demonstrated performance on par with conventional materials, with JLR conducting further validation. Additionally, single-layer pouch cells with 100% recycled cathode and graphite anode materials were produced and integrated into a virtual reality model of the Jaguar I-PACE battery pack, highlighting the practical application of recycled components. An independent Life Cycle Assessment by Minviro confirmed significant environmental benefits, showing that using 100% recycled CAM in NMC 811 cells could reduce greenhouse gas emissions by 32% compared to virgin materials sourced from Asia. Other environmental impacts
energyelectric-vehiclesbattery-recyclingsustainable-materialsEV-batteriescarbon-emissions-reductioncircular-economyGermany bets on AI-powered plant to give used EV batteries a new life
Germany is developing an AI-powered pilot plant in Chemnitz to repurpose used electric vehicle (EV) batteries, extending their lifespans and recovering valuable raw materials such as lithium and cobalt. Led by Dr. Rico Schmerler and his team at Fraunhofer IWU in partnership with EDAG Production Solutions, the initiative focuses on carefully dismantling and remanufacturing traction batteries that retain 70-80% of their capacity but are no longer suitable for vehicles. Instead of shredding, which wastes usable cells and materials, the plant uses automated, AI-supported processes to assess the state of health (SoH) of each battery module and cell, enabling the reuse of healthy components in grid storage systems for homes, businesses, or utilities. The Chemnitz facility aims to address the growing volume of used batteries expected in the EU by 2030, offering a scalable, safe, and efficient solution that preserves raw materials and reduces reliance on energy-intensive new production. Beyond hardware, the plant will
energyAIbattery-recyclingEV-batteriesautomationraw-materialssustainabilitySelf-breaking EV battery material could make recycling fast, easy
MIT researchers have developed a novel “self-assembling” electrolyte material for electric vehicle (EV) batteries that significantly simplifies recycling. Inspired by a Harry Potter scene where Dumbledore cleans a room with a flick of his wrist, the team designed a battery electrolyte that can quickly disassemble when exposed to a simple organic solvent. This allows the battery’s layers to separate naturally, enabling easier sorting and recycling of individual components. Unlike conventional batteries, which are difficult and costly to recycle due to complex and harsh chemical processes, this new approach embraces a “recycle-first” design philosophy, creating materials that prioritize recyclability from the outset. The electrolyte material is composed of aramid amphiphiles (AAs), molecules that self-assemble into durable nanoribbons mimicking the strong chemical structure of Kevlar, combined with polyethylene glycol (PEG) to conduct lithium ions. These nanoribbons form a solid-state electrolyte that is both tough and functional, facilitating lithium-ion transport between the battery’s cathode and
energybattery-recyclingelectric-vehiclessolid-state-batteryelectrolyte-materialsustainable-materialslithium-ion-batteriesToyota gives old EV batteries a second life to power Mazda car plant
Toyota and Mazda have collaborated to test an innovative energy storage system in Japan that repurposes retired electric vehicle (EV) batteries to power Mazda’s Hiroshima car plant. Developed by Toyota, the Sweep Energy Storage System rapidly manages power flow between batteries of varying ages, chemistries, and capacities—including lithium-ion, nickel-metal hydride, and lead-acid cells—without needing separate management units. This approach extends the life of high-voltage battery packs from hybrid and electric vehicles, including those damaged in accidents, by using them as stationary energy buffers to stabilize renewable energy supply and reduce waste. The project aims to demonstrate stable, reliable, and efficient charging and discharging performance, contributing to carbon neutrality by regulating fluctuating renewable energy sources. It also supports the creation of a sustainable battery ecosystem in Japan, addressing industry-wide challenges related to resource security and supply chain resilience. This initiative builds on Toyota’s earlier partnership with JERA, which launched a similar battery storage system in 2022 using reclaimed EV batteries
energyelectric-vehicle-batteriesbattery-storage-systemrenewable-energysustainabilitybattery-recyclingcarbon-neutralityUsed EV batteries turned into solar energy storage units for homes
German company Voltfang is repurposing used electric vehicle (EV) batteries into compact, fridge-sized energy storage units designed to store excess solar and wind energy for homes and businesses. These systems, named Voltfang 2 and Voltfang 2 Indoor, utilize high-performance, requalified battery modules sourced from the European automotive industry. Before reuse, technicians thoroughly test the batteries to assess their remaining lifespan, ensuring only suitable cells are integrated. The resulting storage units act as large power banks, enabling users to feed electricity back into the grid when needed, thereby enhancing energy security and supporting a more resilient, climate-friendly energy infrastructure. Voltfang’s industrial battery storage solutions particularly benefit companies with high energy demands, such as manufacturing, agriculture, office complexes, and EV charging parks. These systems help reduce reliance on external energy suppliers, lower carbon footprints, and optimize energy efficiency. The company recommends pairing the storage units with photovoltaic (PV) systems to maximize surplus energy storage but notes that even without PV
energyenergy-storageEV-batteriessolar-energyrenewable-energybattery-recyclingsustainable-technologyScientists make recycling method for dry-processed Li-ion cathodes
Scientists at the MEET Battery Research Center and the University of Münster have developed an innovative recycling method for dry-processed lithium-ion battery cathodes, advancing sustainable and circular battery production. Unlike traditional wet processing, which uses solvent-based slurries, dry processing employs polytetrafluoroethylene (PTFE) as a binder, eliminating costly and toxic solvents. The new recycling technique leverages mild mechanical milling to delaminate and recover cathode materials from aluminum current collectors without harsh chemicals or high heat, preserving the integrity of active materials and the PTFE binder network for direct reuse in battery manufacturing. This approach not only supports greener battery production but also proves economically viable. Tests demonstrated that electrodes made from recycled materials perform comparably to those from new composites. A life-cycle cost assessment indicated that even at a low scrap rate of 5%, the method reduces electrode processing costs by about 2.6% (approximately USD 0.8 per kWh) and lowers carbon emissions by around 2
energylithium-ion-batteriesbattery-recyclingdry-electrode-processingsustainable-materialscircular-economyEV-batteriesDead EV batteries hold 80% lithium, offering recycling potential
A recent Australian study highlights that discarded electric vehicle (EV) lithium-ion batteries still retain about 80% of their lithium content, presenting a significant opportunity for recycling. Recycling these batteries not only recovers high-purity lithium (near 99%) but also valuable metals like nickel and cobalt. Compared to traditional lithium mining, recycling reduces carbon emissions by 61%, energy use by 83%, and water consumption by 79%, making it a cleaner and more sustainable approach. With the global lithium-ion battery market expected to grow 13% annually and battery waste projected to reach 137,000 tons per year in Australia alone, recycling could address both environmental and economic challenges, including job creation and waste reduction. Despite these benefits, challenges remain, such as rapidly evolving battery chemistries and lagging policy development, which complicate recycling processes. Experts emphasize the need for investment in infrastructure to support a circular economy for lithium batteries. While companies like Belgium’s Umicore, the U.S.’s Redwood
energylithium-ion-batteriesbattery-recyclingelectric-vehiclessustainable-materialscarbon-emissions-reductioncircular-economyChina builds solar catalyst from battery waste to break down plastic
Researchers in China have developed an innovative solar-driven catalyst made from recycled lithium iron phosphate (LFP) batteries to break down polyethylene terephthalate (PET) plastic into valuable monomers. The catalyst, composed of iron oxide (Fe₂O₃) nanoparticles uniformly dispersed on recycled graphite from battery anodes, uses sunlight to generate localized heat that efficiently depolymerizes polyester chains. Under simulated sunlight, this photothermal catalyst achieved a PET conversion rate of 59 percent and a monomer (BHET) yield above 39 percent within an hour, outperforming standard thermal methods by over threefold in conversion and eightfold in yield. The catalyst also demonstrated excellent durability, maintaining over 90 percent efficiency after 15 reuse cycles. The team further validated the catalyst’s practical application by designing an outdoor solar reactor employing a Fresnel lens to concentrate sunlight, reaching temperatures above 190 °C. This setup achieved nearly complete PET conversion (99.8 percent) in just 30 minutes, recovering
energysolar-catalystbattery-recyclingphotothermal-catalysismaterials-scienceplastic-upcyclingsustainable-technologyUS' lithium battery recycling plant offers yield exceeding 97%
Princeton NuEnergy (PNE) has launched the United States’ first commercial-scale battery recycling facility in Chester, South Carolina, achieving a recycling yield exceeding 97%. This advanced plant produces battery-grade cathode active materials and critical battery minerals domestically, supporting a secure and circular U.S. battery supply chain. The facility is fully permitted, surpasses industry recovery norms, and plans to expand capacity from 15,000 tons per annum (tpa) in 2026 to potentially 50,000 tpa as demand grows. PNE’s technology, developed from Princeton University research, utilizes a patented low-temperature plasma-assisted separation process (LPAS) that recovers nearly all lithium-ion materials across battery chemistries, offering a 38% cost reduction and 69% lower environmental footprint compared to conventional methods. PNE is also advancing direct recycling technologies through a joint pilot facility in Texas and operates the largest Materials Testing Center in the U.S. northeast, facilitating third-party validation and accelerating
energybattery-recyclinglithium-batteriesmaterials-recoverycircular-economysupply-chainsustainable-energyUsing retired EV batteries cuts more carbon emissions than recycling
A collaborative study by researchers from the University of Münster, Fraunhofer Research Institution, and Lawrence Berkeley National Laboratory analyzed end-of-life strategies for electric vehicle (EV) batteries in California through 2050. They compared three scenarios: immediate recycling, minimal reuse, and prioritizing second-life use in stationary energy storage before recycling. The findings show that repurposing retired EV batteries as grid-connected storage—especially in regions with high renewable energy penetration—can reduce carbon emissions more significantly than recycling alone. Specifically, second-life use could cut an additional 8 million tons of CO₂ emissions beyond the 48 million tons avoided by direct recycling, totaling 56 million tons of avoided emissions by substituting new battery manufacturing with refurbished packs. However, the study also highlights an impending oversupply of retired EV batteries that will exceed California’s stationary storage demand by mid-century, even when using lithium iron phosphate (LFP) batteries favored for such applications. This surplus underscores the urgent need for early investment in large-scale recycling
energyelectric-vehicle-batteriesbattery-recyclingcarbon-emissions-reductionstationary-energy-storagerenewable-energy-integrationbattery-reuseResearchers uncover atomic flaw blocking lithium battery recycling
Researchers at the Hong Kong University of Science and Technology (HKUST) have identified a critical atomic-level flaw that hinders lithium battery recycling: trace amounts of aluminum contamination within cathode materials. Their study reveals that aluminum atoms infiltrate nickel–cobalt–manganese (NCM) cathodes by substituting cobalt atoms, forming ultra-stable aluminum–oxygen bonds. This atomic substitution effectively locks key metals like nickel, cobalt, and manganese in place, making them significantly harder to extract using the acidic solvents commonly employed in recycling processes. Advanced imaging techniques and quantum modeling confirmed that even minimal aluminum presence fundamentally alters the chemical behavior of cathode materials, posing a substantial obstacle to efficient metal recovery. The research also highlights that aluminum’s impact varies with different solvents—slowing metal release in formic acid, accelerating it in ammonia, and producing unpredictable results in deep eutectic solvents—underscoring the complexity of recycling chemistry. Moreover, common mechanical shredding methods may exacerbate aluminum contamination through friction
energybattery-recyclinglithium-batteriesmaterials-sciencealuminum-contaminationcathode-chemistrysustainable-energyUS tech gives dead EV batteries 85% power after 900 charge cycles
Researchers at Worcester Polytechnic Institute (WPI) have developed an environmentally friendly and scalable hydrometallurgical recycling method for lithium-ion batteries, recovering 92 percent of critical metals such as nickel, cobalt, and manganese. This approach converts spent nickel-lean cathode materials into high-quality cathode powder suitable for reuse in batteries. Batteries made from this recycled cathode powder retained 88 percent of their capacity after 500 charge cycles and over 85 percent after 900 cycles, demonstrating strong performance and longevity. The new method is also energy-efficient, consuming 8.6 percent less energy and reducing carbon emissions by 13.9 percent compared to conventional recycling techniques. This innovation addresses the environmental challenges posed by battery waste and reduces reliance on environmentally damaging mining activities. The research, led by Professor Yan Wang, highlights the potential for creating high-performance batteries from recycled materials at scale, contributing to a more sustainable and resilient battery supply chain essential for supporting renewable energy infrastructure. The findings were published in the journal
energylithium-ion-batteriesbattery-recyclingrenewable-energysustainable-materialshydrometallurgical-methodelectric-vehiclesUS firms to give used EV batteries a second life to feed AI hunger
General Motors (GM) and Redwood Materials have partnered to repurpose used electric vehicle (EV) batteries into large-scale energy storage systems, addressing a critical environmental challenge posed by the upcoming influx of first-generation EV batteries. This initiative supports GM’s sustainability strategy by providing a second life for retired automotive battery packs, which typically retain substantial energy capacity even after falling below optimal levels for vehicle use. The repurposed batteries are integrated into microgrids—localized, independent power grids that offer highly reliable, uninterrupted electricity—crucial for energy-intensive operations such as AI data centers. A notable project in Sparks, Nevada, already powers a 63 megawatt-hour microgrid supplying energy to an AI infrastructure company, marking the largest such installation in North America. The program tackles the growing demand for energy storage solutions driven by the rapid expansion of AI data centers, which are expected to triple their share of U.S. electricity consumption from 4.4% in 2023 to 12% by
energyelectric-vehicle-batteriesenergy-storagemicrogridssustainabilitybattery-recyclingAI-data-centersGM teams up with Redwood Materials to power data centers with EV batteries
General Motors (GM) has partnered with Redwood Materials to repurpose both new and used electric vehicle (EV) batteries for stationary energy storage applications. Redwood Materials processes these batteries by retaining many packs intact—rather than fully recycling them—because testing shows many cells still have significant usable life. These second-life batteries have been integrated into a 12-megawatt microgrid at Redwood’s headquarters in Sparks, Nevada, which supplies electricity to a nearby 2,000 GPU data center operated by Crusoe. The microgrid is powered by solar panels, enabling the storage of excess renewable energy for later use, and is part of Redwood’s broader initiative launched publicly in June to repurpose EV batteries for grid-scale energy storage. Redwood Materials currently recovers about 70% of used or discarded batteries in the U.S. and aims to deploy 20 gigawatt-hours of energy storage capacity by 2028. The company’s ability to integrate various battery packs from different manufacturers and chemistries may
energy-storageelectric-vehiclesbattery-recyclingrenewable-energymicrogridsolar-powerenergy-technologyClean recycling breakthrough turns dead batteries into power for US
The article highlights a significant breakthrough by the US startup Nth Cycle, which has developed an innovative, environmentally friendly method to refine critical industrial metals from battery scrap and electronic waste. Currently, about 85% of global refining of essential minerals like cobalt, nickel, lithium, and rare Earth elements occurs in China, creating a strategic vulnerability for the US in producing electric vehicle batteries, defense equipment, and other advanced technologies. Nth Cycle’s modular, electrically powered refining platform called “The Oyster” uses electro-extraction—a process that replaces traditional high-heat, chemical-intensive refining with electricity and filtration—enabling smaller-scale, localized, and low-emission metal recovery operations across the US and Europe. Nth Cycle’s first commercial unit in Fairfield, Ohio, processes over 3,000 metric tons of scrap annually, producing cobalt and nickel while reducing reliance on foreign refining. The company’s approach, described as “refining as a service,” allows customers to maintain ownership of recovered metals while Nth Cycle operates
energybattery-recyclingcritical-mineralselectro-extractionsustainable-refiningcobalt-recoverynickel-recoveryFriction tech recovers lithium power from dead batteries without waste
Researchers in China have developed a novel recycling method called tribocatalysis that recovers valuable lithium and cobalt from dead lithium-ion batteries without generating toxic emissions or waste. This technique uses friction between surfaces combined with a weak acid to extract metal ions from the battery cathode. Unlike traditional recycling methods—pyrometallurgy, which involves high-temperature burning and releases harmful gases, and hydrometallurgy, which uses strong chemicals and produces toxic byproducts—tribocatalysis operates at low temperatures without harsh chemicals, making it safer, cheaper, and more environmentally friendly. The research, led by Professor Changzheng Hu at Guilin University of Technology and published in the Journal of Advanced Ceramics in June 2025, demonstrated through computer modeling and experiments that tribocatalysis efficiently recycles battery materials while reducing pollution and waste. Given the rapidly increasing demand for lithium-ion batteries driven by electric vehicles and clean energy technologies, this breakthrough offers a promising sustainable solution to conserve scarce resources and mitigate environmental
energylithium-ion-batteriesbattery-recyclingtribocatalysisclean-energysustainable-materialsenvironmental-technologyRedwood Materials launches energy storage business and its first target is AI data centers
Redwood Materials, founded by former Tesla CTO JB Straubel, has launched a new energy storage business called Redwood Energy, targeting AI data centers as its initial customers. The company is repurposing thousands of retired EV batteries—currently stockpiling over 1 gigawatt-hour and expecting an additional 4 gigawatt-hours soon—to create large-scale, clean energy storage systems. Their first project, in partnership with AI infrastructure firm Crusoe, involves a 12 MW, 63 MWh microgrid in Nevada that powers a modular data center using energy stored from an adjacent solar array. This operation is already profitable and marks a significant expansion beyond Redwood’s core battery recycling and materials supply business. Redwood Materials has built a circular supply chain by recycling battery scrap and consumer electronics to extract valuable materials like cobalt, nickel, and lithium, which it then sells to major manufacturers including Panasonic, Toyota, and GM. The company has also moved into cathode production and expanded its footprint globally. Redwood Energy
energyenergy-storageEV-batteriesbattery-recyclingmicrogridAI-data-centersrenewable-energyUS lab uses nano-CT scans to breathe new life into dead EV batteries
Researchers at the US National Renewable Energy Laboratory (NREL) are employing ultra-high-resolution nano-computed tomography (nano-CT) scans to analyze and revive spent lithium-ion batteries from electric vehicles (EVs). This nondestructive imaging technique, capable of resolving features down to 50 nanometers, reveals microscopic cracks and internal defects in battery cathodes that traditional methods miss. These cracks, particularly in nickel-rich cathode particles, impede lithium-ion flow and degrade fast-charging capabilities despite retained energy capacity. By correlating structural damage with performance loss, the team can identify specific degradation patterns and tailor direct-recycling methods that refurbish rather than fully rebuild cathodes. The direct-recycling approach aims to repair damaged cathodes through gentler mechanical treatments that restore cracked particles or replace only damaged sections, preserving the crystal structure critical for high energy density. This method contrasts with conventional recycling, which dissolves electrodes into basic chemicals—an energy-intensive process that also risks losing valuable metals. Successful implementation would reduce processing
energylithium-ion-batteriesbattery-recyclingnano-CT-imagingelectric-vehiclesbattery-materialsNational-Renewable-Energy-LaboratoryA Deeper Look at Hidden Damage: Nano-CT Imaging Maps Internal Battery Degradation - CleanTechnica
The article discusses advances in understanding and improving lithium-ion battery recycling through high-resolution nano-CT imaging, led by researchers at the National Renewable Energy Laboratory (NREL). Lithium-ion batteries rely on scarce and valuable minerals such as lithium, nickel, cobalt, manganese, and graphite, with much of the global supply chain controlled by China. To reduce dependence on foreign markets and extend the lifespan of critical materials, direct recycling of battery cathodes within the United States is being explored as a more efficient and cost-effective alternative to traditional recycling methods, which are energy-intensive and break materials down to their elemental forms. NREL’s nano-CT scanner, capable of 50-nanometer spatial resolution, allows nondestructive, real-time visualization of internal battery structures, revealing microscopic degradation that impacts battery performance. Researchers found that although end-of-life battery materials retained similar energy capacity to new cells, their charging rates were significantly reduced due to morphological damage—specifically, particle cracking within the cathode microstructure. This insight
energybattery-technologylithium-ion-batteriesnano-CT-imagingmaterials-sciencebattery-recyclingenergy-storageLithium battery waste gets AI-powered fix from Hong Kong startup
Hong Kong startup Achelous Pure Metals is addressing the growing global e-waste crisis, particularly lithium-ion battery waste, with an AI-powered, portable recycling system designed for urban centers. The company has developed a robot-assisted pilot line capable of sorting, shredding, and filtering materials from non-electric vehicle lithium batteries. Their process includes vacuum and heat treatments to safely extract hazardous substances and uses nanoparticle-based separation to isolate critical metals like lithium, cobalt, and nickel from the "black mass" residue. Achelous aims to scale and deploy this eco-friendly recycling technology starting in Hong Kong and expanding across Southeast Asia. Despite deploying technology at a client facility in Jiangsu province capable of processing up to 10,000 tonnes of battery waste annually, the startup faces challenges due to oversupply and falling prices of recycled lithium products. Lithium carbonate prices have dropped nearly 90% from late 2022 to mid-2024 amid a surge in China’s recycling capacity and black mass competition. In response, Achelous is pivoting by expanding its Hong Kong operations and helping partners across Southeast Asia establish micro-factories to produce black mass for export to China. The company is also exploring recycling opportunities for lithium batteries from security transceivers and working with local firms in Malaysia and Singapore to meet future recycled content regulations and compliance tracking. This initiative comes amid a mounting global e-waste problem, with 62 million tonnes generated in 2022 and projections reaching 82 million tonnes by 2030. Metals in e-waste are valued at $91 billion, yet only 22% was properly recycled in 2022. Governments worldwide, including the EU, are tightening regulations to increase lithium recovery rates, underscoring the urgent need for innovative recycling solutions like those developed by Achelous Pure Metals.
energylithium-batteriesbattery-recyclingAI-powered-recyclinge-waste-managementmaterials-recoverysustainable-technology