The Need

The rapid growth of electric vehicles and energy storage systems is driving an unprecedented volume of end‑of‑life lithium‑ion batteries, creating both environmental and supply‑chain challenges. Conventional recycling routes focus on metal recovery through energy‑intensive processes and ultimately return materials to commodity precursors, losing embedded value. At the same time, battery manufacturers seek higher‑energy, lower‑cost cathode materials with reduced reliance on nickel and cobalt. There is a clear need for more sustainable, value‑retentive pathways that transform spent cathodes into next‑generation battery materials.

The Technology

OSU engineers have developed a method for direct upcycling of spent or excess NMC lithium‑ion battery cathodes into lithium‑ and manganese‑rich (LMR) layered oxide cathode materials. The method selectively adjusts cathode composition and structure, converting existing NMC materials into a higher‑capacity, next‑generation chemistry while preserving particulate integrity. Importantly, valuable nickel and cobalt are preferentially separated during processing and can be recovered as co‑products. The result is a performance‑enhanced cathode produced through a more resource‑efficient, circular manufacturing approach.

Benefits/Advantages

• Value retention: Converts spent cathodes directly into higher‑performance materials rather than low‑value metal salts
• Resource efficiency: Reduces dependence on freshly mined Ni and Co while enabling their recovery as byproducts
• Performance upside: Delivers higher specific capacity compared to conventional NMC cathodes
• Sustainability: Lower energy and environmental footprint than traditional hydrometallurgical recycling routes