Resilient Recycling of Battery Materials Using Laser Processing

Lithium (Li)-ion batteries are a technology of major importance, powering cell phones and laptops, and now increasingly vehicles. A successful transition to renewable energy requires new recycling methods to ensure the end-of-life for these products does not become an environmental liability. This project initiated a new collaboration to explore Li-ion battery material recycling via laser ablation. We will generate initial data and proof-of-concept on the use of laser ablation for battery electrode recycling and will assess the extent to which constituent components can be selectively extracted for reuse and recycling.

Lasers provide a novel approach to recycling, with a variety of advantages over chemical methods of recovery. Laser systems allow heating materials to extreme temperatures for controlled durations from picoseconds to milliseconds with fine control over the affected area while also using a low energy input. High-power lasers are increasingly used in manufacturing sectors like automobile, aerospace, electronics, biomedical and general manufacturing. High-power laser use continues to grow, and the cost has dropped, making laser processing an attractive solution for large scale applications. Laser ablation can be conducted in both air and liquid, and the process is highly efficient because the locations are targeted.

Effectively recycling and/or reusing these battery materials as efficiently as possible will be critical because 1) massive quantities of EV Li-ion batteries going to landfills provide a fire hazard and potential environmental exposure route for heavy metals and fluorinated compounds, 2) lack of recycling/reuse of the batteries questions the sustainability and net environmental benefits of switching to EVs for transportation, and 3) the spent batteries contain large amounts of elements identified by DOE as of critical need including Li and Co, and other materials of potential recycle value such as Cu, Al, and Ni.