Cornell researchers have developed an electrochemical regeneration process that could recover up to 95% of a spent lithium-ion battery’s original power while significantly reducing recycling costs and environmental impact. Published June 9 in Energy and Environmental Science, the study was led by postdoctoral researcher Kiwon Kim and overseen by Vibha Kalra, Fred H. Rhodes Professor of Chemical Engineering.
Traditional recycling methods rely on high-temperature smelting (pyrometallurgy) or acid-based leaching (hydrometallurgy) to break down shredded battery materials, followed by energy- and resource-intensive resynthesis of electrode components. These approaches extend the recycling “circularity loop,” drive up processing expenses, and often depend on infrastructure that is limited in the United States. They can also produce harmful byproducts and increase water consumption.
To address these challenges, the team introduced a direct electrode-to-electrode regeneration (DEER) technique. Intact electrodes are removed from spent cells and immersed in a solution containing 1,3-dimethyl-2-imidazolidinone. This solvent selectively dissolves the thickened solid electrolyte interphase layer that forms during battery cycling, restoring electrode functionality without shredding or high-temperature treatment. After treatment, the electrodes are reassembled into new cells, demonstrating up to 95% capacity recovery and extended cycle life.
Techno-economic and environmental impact analyses—performed using open-source tools from Argonne National Laboratory’s ReCell Center—indicate that DEER could cut recycled cell manufacturing costs by 56% and reduce air emissions and water use compared to existing methods. The process also addresses supply-chain risks associated with importing critical minerals like nickel and cobalt.
Next steps include scaling the DEER protocol to industrial-scale batteries and tackling additional degradation mechanisms such as lithium loss. Current tests focus on cells with 70%–80% state of health, typical of end-of-life electric vehicle applications. Co-authors on the paper include Shuwen Yue, doctoral student Chenlu Yang, and Sabine Gallagher. The work was supported by the Cornell Atkinson Center for Sustainability and the Pao-Wang Fellowship.
Source: Energy and Environmental Science (https://news.cornell.edu/stories/2026/06/electrochemical-bath-recycles-critical-minerals-batteries)
