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Related Experiment Video

Updated: Apr 11, 2026

Identification and Quantification of Decomposition Mechanisms in Lithium-Ion Batteries; Input to Heat Flow Simulation for Modeling Thermal Runaway
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Toward Sustainable Lithium Recovery: A Universal Hydrothermal Approach for Lithium Extraction.

Zexin Wang1, Jiahui Hou1, Zifei Meng1

  • 1Department of Mechanical and Materials Engineering, Worcester Polytechnic Institute, 100 Institute Road, Worcester, Massachusetts 01609, United States.

ACS Applied Materials & Interfaces
|April 10, 2026
PubMed
Summary

This study introduces a sustainable hydrothermal method for recycling lithium-ion batteries (LIBs). The process efficiently recovers lithium and transition metals, offering a greener and more profitable alternative to conventional recycling.

Keywords:
battery-grade producthigh selectivityhydrothermal reactionlithium-ion batteries recyclingultrahigh efficiencyuniversal feedstock

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Area of Science:

  • Materials Science
  • Chemical Engineering
  • Environmental Science

Background:

  • The escalating deployment of lithium-ion batteries (LIBs) necessitates sustainable end-of-life management strategies.
  • Conventional recycling methods like pyrometallurgy and hydrometallurgy face challenges including high energy consumption, lithium loss, and complex wastewater treatment.
  • There is a critical need for efficient and environmentally friendly methods for recovering valuable materials from spent LIBs.

Purpose of the Study:

  • To develop a universal, highly efficient, and sustainable hydrothermal process for lithium extraction and material recovery from diverse spent LIB cathodes.
  • To evaluate the economic and environmental benefits of the proposed method compared to traditional hydrometallurgy.
  • To demonstrate the feasibility of synthesizing high-performance cathode materials using recovered lithium.

Main Methods:

  • A hydrothermal route utilizing 1,2,4,5-benzenetetracarboxylic acid (BTCA) was employed for lithium extraction from various spent LIB cathode materials.
  • Optimized process parameters were determined to maximize lithium leaching efficiency while minimizing transition metal co-extraction.
  • Recovered lithium was converted into battery-grade sources, and transition metals were recovered as oxides. BTCA regeneration and reuse were also assessed.

Main Results:

  • Over 99% lithium leaching efficiency was achieved for lithium iron phosphate (LFP) and LiNixMnyCo1-x-yO2 (NMC) cathodes, with minimal transition metal leaching (<1%).
  • High lithium recovery rates were also observed for lithium manganese oxide (98.5%), lithium cobalt oxide (98.95%), and black mass (94.06%).
  • The BTCA-based process demonstrated a >40% increase in revenue and up to 39% reduction in greenhouse gas emissions compared to conventional hydrometallurgy.

Conclusions:

  • The developed BTCA-assisted hydrothermal process is a scalable, economically viable, and sustainable solution for industrial LIB recycling.
  • This chemistry-agnostic approach enables efficient resource circularity and reduces reliance on primary critical raw materials.
  • Cathode materials synthesized using recovered lithium demonstrated performance comparable to commercial products, validating the quality of recycled materials.