Lithium-iron-phosphate (LFP) batteries offer a compelling combination of performance characteristics for stationary energy storage, including improved safety and longevity, when compared to other lithium battery chemistries, such as nickel- and cobalt-based formulations. However, there are limited recycling pathways dedicated to end-of-life LFP batteries outside of high-cost hydrometallurgical processes that are challenging to scale with market demand. A new technology developed by NEU Battery Materials (Singapore; www.neumaterials.com) employs an electrochemical redox process to recycle LFP battery materials into battery-grade lithium hydroxide (LiOH) or lithium carbonate (Li2CO3) with much lower costs and carbon emissions than traditional recycling methods.
Source: NEU Battery
The company has developed a proprietary chemical formulation, which is used in a redox reaction to enable the selective extraction of lithium. “Subsequently, the extracted lithium passes into our electrolyzer, which is the next crucial step to facilitate the formation of LiOH through electrolysis. Given that our process leverages water and electricity, our carbon emissions can be 5–6 times lower compared to the traditional methods for lithium battery recycling,” comments NEU Battery Materials’ chief technology officer and co-founder Kenneth Palmer.
Most lithium-ion batteries are recycled using hydrometallurgical or pyrometallurgical processes, which require high-temperature smelting and leaching with harsh acids, generating substantial waste volumes. “The higher operating costs for these processes mean that traditional recyclers must prioritize recycling nickel- and cobalt-based batteries. Our technology allows us to focus specifically on recycling the fast-growing market share of LFP batteries,” notes Palmer.
In addition to lower energy costs and emissions, the redox-electrochemical process requires no harsh chemicals and is highly modular, meaning that recycling capacity can be flexibly scaled as needed to meet demand. “We have taken the technology from the research laboratories at the National University of Singapore up to pilot-scale operations of around 200 tons of batteries per year. We are currently in the process of constructing a semi-commercial facility with at least 1,300 tons of capacity. This facility will be able to recycle a range of LFP materials into battery-grade lithium,” explains Palmer.