WPI Develops Cleaner Lithium-Ion Battery Recycling Process

Researchers at Worcester Polytechnic Institute (WPI), led by Professor Yan Wang, William B. Smith Professor of Mechanical and Materials Engineering, have developed a scalable method for recycling lithium-ion batteries that improves efficiency and reduces environmental impact.

The team’s study, Upcycling Mixed Spent Ni-Lean Cathodes into Ni-Rich Polycrystalline Cathodes, published in Energy Storage Materials, outlines a hydrometallurgical upcycling process designed to recover and repurpose materials from spent mixed nickel-lean (Ni-lean) cathodes—common in used lithium-ion batteries. Traditional recycling techniques often struggle to reclaim these materials effectively, relying on energy-intensive processes that produce lower-value outputs.

The WPI process recovers more than 92% of nickel, cobalt, and manganese, converting them into high-performance cathode powders. Batteries made with these recycled materials demonstrate performance comparable to those using virgin inputs, retaining 88% capacity after 500 charge cycles and over 85% capacity after 900 cycles in commercial-scale pouch cells.

In addition to performance benefits, the method consumes 8.6% less energy than conventional hydrometallurgical recycling and reduces carbon emissions by 13.9% compared with traditional recycling approaches. This aligns with goals to minimize environmental impact while meeting the growing demand for critical materials in electric vehicle and renewable energy storage applications.

According to Professor Wang, the process addresses both the environmental burden of battery waste and the dependence on mining for critical minerals, offering a pathway toward a more sustainable and resilient battery supply chain.

About Worcester Polytechnic Institute (WPI)

Founded in 1865 and based in Worcester, Massachusetts, Worcester Polytechnic Institute is a private research university known for integrating science, engineering, technology, and business education with real-world problem solving. WPI engages in interdisciplinary research addressing global challenges in areas including sustainable energy, advanced manufacturing, and materials innovation. For more information, visit www.wpi.edu.

Source/Photo Credit: Worcester Polytechnic Institute

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