The demand for lithium has quadrupled in just over a decade, mainly due to technological advances. According to industry data, more than 150 million lithium batteries could be wasted by 2035. In light of these figures, a team from Princeton University has proposed a solution: rejuvenating lithium-ion batteries.
The study: Princeton NuEnergy researchers recently developed a new regeneration system for recycling lithium-ion batteries, achieving a remarkable 95% recovery rate.
What method did they use? Experts have discovered that low-temperature plasma can replace traditional recycling processes that rely on extreme heat and liquid chemicals.
First, the team separates the battery components, including copper, aluminum, plastic, cathode, and anode. Then, the low-temperature plasma-assisted separation (LPAS) process begins. Only the cathode and anode are used during the process, and impurities are removed to enable rejuvenation and reuse. According to Princeton NuEnergy, this method consumes 73% less energy, emits 68% fewer greenhouse gases, and uses 69% less water than conventional recycling methods.
After the LPAS process restores the functionality of the electrodes, researchers employ micro-molten shell-assisted lithiation. In this process, recycled materials receive lithium in precise amounts to enhance their performance to levels comparable to those of new batteries.
There’s more. The university will develop the U.S.’ first commercial plant aimed at recycling lithium-ion batteries using its patented technology. The plant will be located in South Carolina and is expected to commence operations in the third quarter of 2028.
Battery recycling. This isn’t a new concept. Given the high demand and difficulty of extracting lithium, scientists have developed various methods to reuse it. For example, it’s possible to leach 87% of the lithium from battery waste. Additionally, researchers are exploring alternatives such as aluminum, sulfur, redox, and solid-state flux.
Can the LPAS process be applied to other elements? Researchers at Princeton have demonstrated that conventional recycling techniques don’t adapt well to the changing compositions of battery electrodes. In contrast, the LPAS process has proven effective for recycling the following types of batteries: NMC (nickel, manganese, and cobalt); NCA (nickel, cobalt, and aluminum oxide); LFP (lithium, iron, and phosphate); and LCO (lithium, cobalt, and oxide).
Image | Roberto Sorin
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