Scientists make recycling method for dry-processed Li-ion cathodes

Scientists at the MEET Battery Research Center and the University of Münster have developed an innovative recycling method for dry-processed lithium-ion battery cathodes, advancing sustainable and circular battery production. Unlike traditional wet processing, which uses solvent-based slurries, dry processing employs polytetrafluoroethylene (PTFE) as a binder, eliminating costly and toxic solvents. The new recycling technique leverages mild mechanical milling to delaminate and recover cathode materials from aluminum current collectors without harsh chemicals or high heat, preserving the integrity of active materials and the PTFE binder network for direct reuse in battery manufacturing. This approach not only supports greener battery production but also proves economically viable. Tests demonstrated that electrodes made from recycled materials perform comparably to those from new composites. A life-cycle cost assessment indicated that even at a low scrap rate of 5%, the method reduces electrode processing costs by about 2.6% (approximately USD 0.8 per kWh) and lowers carbon emissions by around 2