ARKANSAS, Oct 20 (Future Headlines)- In a significant development in the world of battery recycling, ACE Green Recycling (ACE) and the US Department of Energy’s National Renewable Energy Laboratory (NREL) have formalized a Cooperative Research and Development Agreement (CRADA). This collaboration aims to advance and optimize ACE’s innovative, environmentally friendly, and cost-effective lithium-ion battery recycling technology. The focus is on recycling crucial materials such as graphite, lithium, and lithium-iron-phosphate (LFP) used in the cathodes of lithium-ion batteries. This partnership gains prominence due to the increasing adoption of LFP-based electric vehicles by major manufacturers like Tesla and Ford, driven by the cost-effectiveness of LFP batteries. However, recycling LFP batteries, particularly extracting valuable materials like lithium and graphite, presents unique challenges.

Automotive giants like Tesla and Ford are transitioning from nickel- and cobalt-based batteries to lithium-iron-phosphate (LFP) batteries due to their cost-efficiency. This shift is expected to increase the volume of LFP-based electric vehicles in the coming years.

Recycling LFP batteries presents specific challenges, primarily related to the profitable extraction of valuable materials, such as lithium and graphite. The recycling industry recognizes the complexity of recycling LFP batteries effectively.

Present hydrometallurgical recycling methods primarily target the extraction of high-value materials like lithium and copper. However, there is a need for a more holistic approach to recycling, addressing low-value materials such as graphite and iron-phosphate to create commercially viable products.

ACE has developed proprietary technology for recycling LFP batteries at the bench scale. This technology is currently in the process of scaling up for commercial use. The CRADA with NREL is designed to facilitate the commercialization of ACE’s process for recycling LFP batteries. Moreover, it aims to explore the upcycling of graphite into battery-grade material.

Under the research agreement, NREL, with its expertise in cell production, modeling, analysis, and advanced tools, will contribute its capabilities to evaluate ACE’s technology. The primary research activities will take place at NREL’s facility in Colorado.

The collaborative project’s overarching goal is to identify optimal recycling parameters for LFP and graphite. These parameters should maximize the performance and lifetime of batteries manufactured from recycled materials using ACE’s technology in comparison to those using virgin materials.

The project holds the potential for upcycling graphite derived from ACE’s recycling technology. This could address the United States’ reliance on over 60,000 metric tons of imported graphite electrodes while reinforcing domestic technological leadership and reducing dependence on foreign supply chains.

The partnership between ACE Green Recycling and NREL signifies a remarkable step forward in the realm of lithium-ion battery recycling. With the shift towards cost-effective LFP batteries in the electric vehicle industry, the challenges of effectively recycling these batteries have become evident. ACE’s innovative recycling technology, along with NREL’s research and development capabilities, has the potential to revolutionize the recycling landscape. Their collaborative efforts to optimize recycling parameters and explore graphite upcycling promise to reduce waste, enhance sustainability, and promote self-sufficiency in the lithium-ion battery industry. This partnership sets the stage for a more environmentally friendly and economically viable future in battery recycling.

Reporting by Kevin Wood; Editing by Sarah White