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Li-ion battery recycling by energy-efficient, high-throughput Li2SO4 salt splitting in a diaphragm flow cell

Jason W. Misleh, J. Gage Wright

2026enbattery recyclingelectrochemistrysustainabilitylithiumprocess innovation

Abstract

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Rapidly growing demand for lithium-ion batteries (LIBs) necessitates a significant expansion of LIB recycling to ensure adequate supply and avoid waste buildup. Traditional hydrometallurgical LIB recycling processes use super-stoichiometric quantities of acid and base and generate large volumes of salt waste that pose an environmental burden. Electrochemical regeneration of acid and base from salt offers a zero-waste alternative but faces challenges with respect to throughput and energy consumption, with current densities typically limited to ≤ 100 mA/cm2 and energy demands > 0.10 kWh/mol. These limitations stem from a reliance on ion exchange membranes (IEMs), which lead to high cell resistance. This study reports a hydrometallurgical process to recycle lithium cobalt oxide (LCO) and lithium nickel manganese cobalt oxide (NMC) cathodes using acid and base electrochemically generated from a Li2SO4 electrolyte. The electrochemical cell used contains no IEMs, enabling excellent energy efficiency between 0.033 and 0.097 kWh/mol at current densities up to 500 mA/cm2.

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Cite This Work

@article{c8c8bf79-d5e7-4145-81a1-99a5bb5f2a84,
  title={Li-ion battery recycling by energy-efficient, high-throughput Li2SO4 salt splitting in a diaphragm flow cell},
  author={Jason W. Misleh and J. Gage Wright},
  year={2026},
  language={en}
}
TY  - JOUR
TI  - Li-ion battery recycling by energy-efficient, high-throughput Li2SO4 salt splitting in a diaphragm flow cell
AU  - Jason W. Misleh
AU  - J. Gage Wright
PY  - 2026
LA  - en
ER  -

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