Upcycling Lithium-Ion Batteries

Lithium-ion batteries have become a cornerstone of the shift to sustainable energy, powering everything from smartphones to electric vehicles, as well as providing storage for renewable power from sources like solar and wind. But producing the batteries themselves creates a wide range of environmental issues, and supplies of the raw materials needed to make them are dwindling, so recycling the components is key to maintaining supply.

It has generally been believed that recycled batteries would not perform as well as newly manufactured ones, but recent research has shown just the opposite. A new upcycling process that focuses on removing impurities from the cathode actually results in a battery that can charge faster and last longer than a new one.

Examination of the recycled cathode powder revealed a more porous structure. Larger voids within the cathode crystal allow it to expand slightly as it absorbs the lithium ions, preventing it from cracking and prolonging its life. The greater number of pores also increases the surface area available, allowing for faster charging. The process is so successful that it may be used to improve performance in new batteries as well.