New recycling process restores used batteries to 95% power

Researchers at Cornell University have developed a recycling method that can restore used lithium-ion battery electrodes to as much as 95% of their original power.

The process, called direct electrode-to-electrode regeneration, places intact spent electrodes in an electrochemical solution. This repairs and refreshes the active materials rather than melting batteries at high temperatures or crushing them into a powder that must later be chemically processed and rebuilt.

According to the research team, the approach could reduce recycling costs by 56% and produce batteries that last longer when reused. It may also avoid some of the harsh chemicals, energy use and lengthy manufacturing stages associated with conventional recycling.

This matters because electric vehicles, electronics and renewable-energy storage rely on minerals such as lithium, nickel and cobalt. Those resources are limited, and discarded batteries can create pollution and fire risks. A cheaper, more direct recycling process could keep valuable materials in circulation, reduce pressure on mining and make the clean-energy transition less wasteful.