Farasis Energy validates its lithium-ion battery recycling course of

By Chris Crowell May 2, 2022 View Profile

Lithium-ion batteries have gained extensive acceptance within the renewable area, however an often-cited short-coming of the expertise, nonetheless, is its recyclability. But final week, Farasis Energy despatched phrase that its Direct Recycling means of lithium-ion batteries was nearly prepared for primetime.

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Farasis Energy has been creating its Direct Recycling course of for used lithium-ion batteries for about 10 years now. The recycling technique allows direct restoration and reuse of invaluable supplies from these batteries and from cell manufacturing scrap. Most notably, Farasis has been in a position to efficiently show that recycled cathode materials could be recovered from complete used cells or battery manufacturing scrap after which built-in into new cells.

Key issue: Directly recovering the lively cathode materials powder retains the excessive worth of the unique engineered cathode materials – probably the most costly parts in cell manufacturing – with out the necessity for re-synthesis. This leads to each price and energy financial savings. When utilized to cell manufacturing, scrap can enhance the cathode powder utilization effectivity to over 99 p.c.

Farasis has proven that cells containing as much as 25 p.c recycled cathode materials can exhibit equal efficiency to cells produced from pure virgin cathode materials. Internal testing and exterior validation of pattern 2Ah cells by a US-DOE National Laboratory have proven that even after 600 cost/discharge cycles the cells containing recycled cathode proceed to carry out equally to their pristine counterparts.

The Direct Recycling course of thus makes it doable to considerably cut back the utilization and amount of recent cathode lively materials with out compromising the efficiency of the newly produced batteries. At the identical time, it contributes to a extra environmentally pleasant and sustainable technique of cell manufacturing whereas lowering the general CO2 footprint.

“Our goal is to develop a closed-loop value chain of the battery throughout its lifecycle – from design to end of life management,” says Dr. Keith Kepler, CTO and co-founder of Farasis. “We have made significant progress toward this goal with the validation of our direct recycling process.”

Recent advances in its Direct Recycling course of improvement will allow Farasis to implement economically possible restoration of essentially the most invaluable lively supplies from cells, batteries and battery manufacturing scrap. The subsequent step is to validate sure cathode recycling course of capabilities on a a lot bigger scale, with the intention of enabling Farasis to start recycling the cathode electrode scrap that’s produced throughout cell manufacturing.

Farasis has two U.S. patents and a number of analysis grants, together with a $1.76 million improvement contract awarded by the United States Advanced Battery Consortium (USABC).

Another secret’s their technique is much less energy intense: Most industrial recyclers of lithium-ion batteries deal with both high-temperature smelting or chemical dissolution of the carefully-engineered cathode materials, and recovering solely the person metals. These recycling strategies are energy intensive and impart a major damaging impression to the atmosphere.

The Direct Recycling course of allows full restoration of the high-grade cathode materials in its authentic crystalline type, which suggests the lively materials for cathodes is recovered intact and can be utilized instantly once more within the manufacturing of recent lithium-ion cells.

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