ALBUQUERQUE, N.M. — Researchers at Sandia National Laboratories are developing a new way to reuse old lithium-ion batteries by transforming them into upgraded materials for future use.
The process uses a specialized microwave-based method to break down battery components known as cathodes — a key part of lithium-ion batteries that rely on materials like lithium and cobalt. Instead of traditional recycling, which can be time- and energy-intensive, this approach “upcycles” the material, improving it to meet current industry needs.
Scientists say the technique can reduce processing time from about seven days to just two hours while converting as much as 95% of the material into a usable form. The method also allows researchers to adjust the chemical makeup of the material, including replacing some cobalt with more widely available metals like nickel.
Cobalt remains a critical component in many batteries, but most of the world’s supply is sourced from a limited number of countries. Researchers say finding ways to reuse materials domestically could help reduce reliance on overseas supply chains.
The work also addresses a growing challenge as more electric vehicle batteries reach the end of their lifespan. Rather than sending those materials to landfills, scientists say they could become a valuable resource for the next generation of energy storage.
The Sandia team is continuing to refine the process and study its economic viability, with early results showing potential for large-scale use. Researchers are also exploring partnerships with industry to further develop the technology.
