Advances in lithium-ion battery recycling enhance critical metal recovery and reduce carbon emissions
Lithium-ion batteries (LIBs) are widely used in consumer electronics, electric vehicles, and renewable energy systems, making efficient recycling crucial for sustainability. A research team led by Prof. Dan Tsang, Professor of Civil and Environmental Engineering at The Hong Kong University of Science and Technology (HKUST), has revealed a previously unrecognized atomic-scale mechanism that obstructs efficient LIB recycling.
This breakthrough, now published in Advanced Science, challenges long-standing assumptions and sets the stage for cleaner, high-yield recovery of critical metals used in LIBs.
Through advanced characterization and first-principles modeling, the research team found that aluminum (Al) impurities—which come from the mechanical disassembly of LIBs during the recycling process—penetrate NCM (nickel–cobalt–manganese) cathode crystals and restructure the cathodes’ internal chemistry.
This triggers the formation of ultra-stable aluminum–oxygen bonds, immobilizing valuable metals and suppressing the metals’ leachability, making extraction more difficult, especially in acidic solvent systems commonly used in hydrometallurgy (the use of water-based solutions to extract metals).
Underrated impact: Aluminum as a hidden barrier to recycling
For decades, the presence of aluminum in spent (i.e., used) LIBs has been considered an operational nuisance or a minor issue—now, it has proven to be a mechanistic disruptor that can significantly hinder recycling efforts. The HKUST researchers discovered that during the mechanical disassembly of LIBs, residual aluminum foil can infiltrate NCM (nickel–cobalt–manganese) cathode crystals through frictional contact, subtly but profoundly altering the cathodes’ internal chemistry.
Using advanced microscopy and density functional theory (DFT) modeling, the team found that aluminum atoms selectively replace cobalt, forming highly stable aluminum–oxygen bonds that anchor lattice oxygen and suppress the release of critical metals like nickel (Ni), cobalt (Co), and manganese (Mn) during leaching, making them harder to extract in recycling.
Prof. Tsang, said:
We’ve shown that even tiny amounts of aluminum contamination can fundamentally shift how NCM materials behave in recycling systems,
“This demands a paradigm shift in how we manage impurity pathways in battery-to-battery recovery.”
The study further revealed that the types of solvent used in the recycling process affect how aluminum behaves, demonstrating solvent-dependent effects. For example, aluminum slows down metal release in formic acid, enhances it in ammonia, and leads to mixed outcomes in deep eutectic solvents—highlighting the need for precise chemistry-driven process design.
Building the future of circular batteries
Together, these discoveries form a coherent roadmap to overcome two critical bottlenecks in LIB recycling: impurity interference and energy intensity. By combining precision impurity analysis with smart decomposition strategies, the research equips industry and policymakers with the tools needed to scale sustainable battery recovery systems.
Prof. Tsang emphasized, said:
We’re not just solving problems—we’re reframing what efficient, climate-aligned battery recycling looks like,
These innovations also align with the United Nations Sustainable Development Goals (SDGs), particularly those focused on responsible consumption and production, affordable and clean energy, and climate action.
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Advances in lithium-ion battery recycling enhance critical metal recovery and reduce carbon emissions, source
