Cathode-Healing for Recycling and Manufacturing of Lithium-ion Batteries
OnTo Technology LLC
Recipient
Bend, OR
Recipient Location
$235,539
Amount Spent
Active
Project Status
Project Update
OnTo obtained end of life batteries from Kokam (NMC), Winston (LFP), and A123 (LFP) and begun testing the cathode healing process. Current cathode samples were sent to Saft and Oregon State University for further evaluation. The project team is working on data analysis to prove consistency in LFP processing.
The Issue
The lithium-ion battery (LIB) industry is growing rapidly and is producing large volumes of waste batteries that are projected to grow significantly as more products reach end of life (EOL). There are no cost-positive recycle services available today. Conventional recycling processes produce metal sulfates which are pricier than mined materials and typically do not meet purity specifications for battery manufacturing. Furthermore, batteries with lithium iron phosphate (LFP) cathodes commonly used in large format batteries (e.g., in buses and utility ESS) cannot be recycled economically using any of the current recycling technologies. Novel direct recycling offers an efficient solution, but the performance of batteries made with recovered materials requires demonstration to build manufacturer confidence.
Project Innovation
This project will improve and scale-up patented hydrothermal direct recycling processes for lithium-ion batteries with different cathode chemistries. The project will target advancements in: 1) efficient and accelerated sorting, separation, and de-energization strategies; 2) high rates (kg/day) of cathode/anode separation; 3) low temperature cathode regeneration; and 4) up-cycling of recovered materials into new battery cells. The project will complete life cycle analysis and technoeconomic analysis using tools from Argonne National Laboratory to evaluate environmental benefits and revenue potential for different cathode chemistries and recycling process configurations.
Project Goals
Project Benefits
Affordability
The project aims to achieve operational costs of less than $5/kg for cobalt-containing cathodes and less than $2/kg for non-metal cathodes and anodes, which is at least a 10x reduction compared to market prices of cathodes made from mined materials.
Energy Security
The core innovation is the low temperature hydrothermal cathode re-lithiation process, which the applicant has patented and currently operates at lab scale (~10-100 grams/day) with the project goal to scale this to kg/day steady state operations. Project partner Smartville will evaluate innovative collection, sorting, and dis-charging approaches. The low temperature process requires less energy than established and competing technologies.
Reliability
New batteries for stationary storage made with recycled materials can potentially provide grid reliability benefits with equivalent safety and performance as batteries made from mined materials at a lower cost.
Subrecipients
Electric Power Research Institute, Inc.
Oregon State University
Renewance Inc.
Saft America, Inc.
Global Risk Intelligence and Planning (GRIP, Inc.)
Schnitzer Steel Industries, Inc.
Heritage Battery Recycling, LLC
Match Partners
Oregon State University
OnTo Technology LLC
Schnitzer Steel Industries, Inc.
Greentec Auto
