SBIR-STTR Award

This Small Business Technology Transfer Phase I project advances a cost-effective and scalable direct recycling method for producing battery-grade cathode materials from end-of-life (EOL) lithium-ion batteries. The commercialization of the proposed direct lithium-ion battery recycling technology will lower the energy consumption and emissions associated with battery production, reduce demand for raw battery materials and decrease lithium-ion battery manufacturing cost. Using directly recycled materials instead of raw battery materials will diminish or even avoid the negative environmental impacts from mining and processing ores and from disposal of hazardous waste. Reducing battery cost will facilitate the implementation of more efficient electrified vehicles, thus reducing petroleum demand and vehicle emissions. Finally, research on the end-of-life lithium-ion battery cathode, on the direct recycling process and on the recycled materials will advance the understanding of intercalation chemistry in nonaqueous and aqueous media and of electrode degradation during electrochemical cycling. The intellectual merit of this project is to advance the direct recycling technology through the design and demonstration of a scalable electrochemical flow system capable of non-destructive relithiation and the optimization of post treatment operation for the recovered materials. The electrochemical flow system is capable of restoring the lost lithium in the EOL cathode material at any state of charge (SOC) and can be scaled to a commercially viable size. The cathode materials recovered in the proposed direct recycling process retain the same structure and morphology and exhibit equivalent electrochemical performance compared to the commercial virgin cathode materials. The recovery of high-value cathode materials substantially improves the profitability of lithium-ion battery recycling and is a key element of the business plan.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

The broader impact/commercial potential of this SBIR Phase II project is to significantly improve the economics of lithium-ion battery (LIB) recycling, while minimizing its environmental impact. Direct recycling uses less energy and generates less pollutive waste and fewer emissions than alternative recycling approaches, while simultaneously producing more valuable products. The proposed project will advance the development of a recycling technology that will lower LIB cost, reduce the reliance of LIB production on the mining of expensive virgin metals, create a local supply of LIB materials, and facilitate the adoption of clean energy products (e.g., electric vehicles, grid storage). This SBIR Phase II project proposes to develop a cost-effective and scalable direct recycling process at a pilot-scale level. The proposed project will study LIB deactivation, component separation, purification, and regeneration processes that can be economically reproduced on a large scale. For example, a battery deactivation process that is quicker, safer, and cost-effective can be used in other waste management processes as well to discharge batteries. This project also will enable a better understanding of the key parameters of electrode extraction and purification processes able to preserve electrode chemistry and morphology. By focusing on the characterization of structure, morphology and electrochemical performance of the recycled materials, this project will lead to a more profound understanding of the effect of relithiation and heat treatment conditions on the quality of recycled cathode materials. Together, these studies will advance the knowledge and understanding of not only the process, chemistry, and mechanics behind the direct recycling process but also process optimization for a production-scale LIB recycling operation. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.