Houston scientists develop 'recharge-to-recycle' reactor for lithium-ion batteries

reduce, recharge, recycle

Rice University scientists' “recharge-to-recycle” reactor has major implications for the electric vehicle sector. Photo courtesy Jorge Vidal/Rice University.

Engineers at Rice University have developed a cleaner, innovative process to turn end-of-life lithium-ion battery waste into new lithium feedstock.

The findings, recently published in the journal Joule, demonstrate how the team’s new “recharge-to-recycle” reactor recharges the battery’s waste cathode materials to coax out lithium ions into water. The team was then able to form high-purity lithium hydroxide, which was clean enough to feed directly back into battery manufacturing.

The study has major implications for the electric vehicle sector, which significantly contributes to the waste stream from end-of-life battery packs. Additionally, lithium tends to be expensive to mine and refine, and current recycling methods are energy- and chemical-intensive.

“Directly producing high-purity lithium hydroxide shortens the path back into new batteries,” Haotian Wang, associate professor of chemical and biomolecular engineering, co-corresponding author of the study and co-founder of Solidec, said in a news release. “That means fewer processing steps, lower waste and a more resilient supply chain.”

Sibani Lisa Biswal, chair of Rice’s Department of Chemical and Biomolecular Engineering and the William M. McCardell Professor in Chemical Engineering, also served as co-corresponding author on the study.

“We asked a basic question: If charging a battery pulls lithium out of a cathode, why not use that same reaction to recycle?” Biswal added in the release. “By pairing that chemistry with a compact electrochemical reactor, we can separate lithium cleanly and produce the exact salt manufacturers want.”

The new process also showed scalability, according to Rice. The engineers scaled the device to 20 square centimeters, then ran a 1,000-hour stability test and processed 57 grams of industrial black mass supplied by industry partner Houston-based TotalEnergies. The results produced lithium hydroxide that was more than 99 percent pure. It also maintained an average lithium recovery rate of nearly 90 percent over the 1,000-hour test, showing its durability. The process also worked across multiple battery chemistries, including lithium iron phosphate, lithium manganese oxide and nickel-manganese-cobalt variants.

Looking ahead, the team plans to scale the process and consider ways it can sustain high efficiency for greater lithium hydroxide concentrations.

“We’ve made lithium extraction cleaner and simpler,” Biswal added in the release. “Now we see the next bottleneck clearly. Tackle concentration, and you unlock even better sustainability.

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Ace Green Recycling Inc. will build one of India's largest battery recycling facilities and plans to develop a flagship battery recycling plant in Texas. Photo courtesy Ace Green Recycling Inc.

Houston battery recycling co. expands globally with new India facility, Africa partnership

going global

Ace Green Recycling Inc., a Houston-operated sustainable battery recycling and technology solutions provider, announced it has finalized a lease agreement for a location to build one of India's largest battery recycling facilities in Mundra, Gujarat.

The facility will expand Ace's existing Indian commercial operations, which have been recycling lithium-ion batteries since 2023, including lithium iron phosphate ("LFP") chemistries.

The deployment of Ace’s LithiumFirst LFP battery recycling technology in India will coincide with the deployment of the company's technology in Texas. Last year, the company announced it planned to develop a flagship battery recycling plant in Texas for lead and lithium-ion batteries.

Ace also plans to establish 10,000 metric tons of LFP battery recycling capacity per year in India by 2026. The Mundra LFP battery recycling facility is expected to create up to 50 jobs.

The new facility plans to use Ace's LithiumFirst technology to recycle LFP batteries at room temperature in a fully electrified hydrometallurgical process that produces no direct (or Scope 1) carbon emissions and with zero liquid and solid waste.

"Ace's innovative technology enables profitable recycling of LFP batteries, even with the current low lithium price, by recovering significant amounts of these critical minerals,” Vipin Tyagi, Chief Technology Officer of Ace, said in a news release. “We believe that our successful operational demonstration positions us for future partnerships and collaborations that will unlock the full potential of our LithiumFirst technology in this market.”

Ace will also utilize its GreenLead recovery technology to recycle lead batteries at the new recycling park. The technology is considered a more environmentally friendly alternative to conventional smelting operations.

The company also reported visiting China for possible future expansion. According to a release, it launched a facility in Taiwan last year and is developing projects in Europe and Israel, as well.

Today, the company also announced that it was tapped by Spiro, one of Africa’s largest EV battery producers, as its global preferred recycling partner. According to a release, Ace will recycle end-of-life lithium-ion batteries, including LFP batteries, and waste from Spiro's battery manufacturing facilities.

Ace Green Recycling Inc. is headquartered in Houston and Singapore.

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Houston trio lands on Time’s list of 10 most influential energy companies

making an impact

Three companies with headquarters in Houston made Time magazine’s new list of the 10 most influential energy companies.

The unranked list includes:

Houston-based oil and gas giant Chevron
Houston-based Fervo Energy, a geothermal power provider that just went public in a $1.9 billion IPO
Saudi Aramco, the world’s largest oil company, whose U.S. headquarters is in Houston

In naming Chevron to the list, Time cites the company’s standing as the only major American oil company operating in Venezuela. Time says Chevron wields “extraordinary power” over Venezuela’s massive oil reserves.

Despite pressure from the White House on U.S. oil and gas producers to ramp up investments in Venezuela, “Chevron has pumped the brakes, pledging to boost output gradually and not chase price fluctuations,” Time says.

“Chevron has been in Venezuela for over a century,” CEO Mike Wirth told shareholders in January. “We remain committed to leveraging our deep expertise and long-standing partnerships for the benefit of our shareholders and the people of Venezuela.”

Time points out that Fervo sits “at the front of the pack” in generation of geothermal energy. The Houston-based company uses fracking techniques borrowed from the oil and gas industry to create underground hot-rock reservoirs that heat water to generate electricity.

Fervo’s Cape Station in Utah is scheduled to start delivering power to the grid this year. At full capacity of 500 megawatts, it will be the first large-scale commercial geothermal plant in the U.S. Time says another site in Utah, Project Blanford, is Fervo’s hottest well yet, highlighting the potential for harnessing geothermal heat for at-scale clean energy.

“It’s hard to find something that can [deliver] reliable 24/7 energy, that’s carbon-free, and can be constructed in a timely manner,” Fervo CEO Tim Latimer said. “It’s energy without a lot of the compromises.”

Government-owned Saudi Aramco, which last year earned $104.7 billion in profit, not only is a dominant player in the Mideast oil and gas sector, but Time says it holds “global clout in politics and business” that reaches far beyond oilfields. For example, the company finances big projects spearheaded by Crown Prince Mohammad Bin Salman, who chairs Saudi Arabia’s sovereign wealth fund. These include initiatives in global sports, tourism, and AI.

Baker Hughes teams up with Oklahoma co. to advance geothermal development

geothermal partnership

In recent months, Houston-based energy corporation Baker Hughes has launched multiple partnerships to expand geothermal energy extraction across the United States. The latest, a deal with Oklahoma-based Helmerich & Payne Inc. (H&P), was announced Wednesday.

As part of the deal, H&P will provide a geothermal-capable land drilling rig, while Baker Hughes will contribute technology and expertise. The rig is expected to be deployed later this year, according to a news release.

“Geothermal energy plays a critical role in meeting growing power demand by providing clean, reliable baseload generation,” Amerino Gatti, executive vice president of oilfield services & equipment for Baker Hughes, said in the release. “This collaboration reflects a deliberate step to move its development in the U.S. from concept to reality. By working together, Baker Hughes and Helmerich & Payne are helping customers advance these critical energy projects with greater confidence and deliver reliable, sustainable power.”

Investment in the geothermal energy sector is currently exploding in the U.S., having grown by at least 1,000 percent just in the last seven years, according to a recent report by Rocky Mountain Institute.

On one hand, only about 1 percent of the American energy grid currently uses geothermal, but on the other, the U.S. holds roughly 25 percent of the world’s geothermal capacity. Harnessing that power becomes even more attractive as conflicts in Russia and Iran continue to hamstring energy markets from those countries and revitalize interest in renewable energy.

Baker Hughes has been at the forefront of the geothermal boom. This new deal with H&P combines H&P’s drilling platform technology with Baker Hughes’s subsurface and energy extraction support technologies.

“This agreement underscores Helmerich & Payne’s commitment to supporting emerging energy opportunities through our drilling technologies and operational expertise,” H&P President and CEO Trey Adams added in the release. “We are pleased to collaborate with Baker Hughes to support the advancement of geothermal development in the United States.”

The deal with H&P is just one of several recent ones Baker Hughes has closed. In March, they announced support for XGS’s geothermal extraction projects in New Mexico, which are being used to meet the increasing demands of data centers in the state. Last May, Fervo Energy selected Baker Hughes to supply equipment for its flagship geothermal project in Utah.

Houston renewables developer signs agreement with Meta for new solar project

power deal

Houston-based EDP Renewables North America has signed a long-term power purchase agreement with Meta, the parent company of Facebook and Instagram, for its forthcoming Cypress Knee Solar project.

The 250‑megawatt solar project will be built in Arkansas and is expected to come online by 2028, according to a news release from EDPR. The company says the project will generate approximately $25 million in new revenue for Chicot County once operational.

“Cypress Knee Solar and our broader portfolio of projects with Meta are helping power a reliable, modern U.S. electric grid—the backbone of American innovation and long-term economic growth,” Sandhya Ganapathy, CEO of EDPR NA, said in the release. “These investments strengthen local communities, create durable economic value, and ensure that progress is built on a resilient, sustainable foundation.

This is Meta's third power purchase agreement with EDPR. The tech giant is now contracted to a renewable capacity of 545 megawatts with EDPR. Meta and EDPR also collaborated on the 200-megawatt Brittlebush Solar Park to support Meta's data center in Mesa, Arizona.

“Through our partnership with EDPR, Cypress Knee Solar will bring new generation to the Arkansas grid, creating local jobs and delivering economic benefits to the community. We’re proud to expand our collaboration with EDPR,” Amanda Yang, head of clean and renewable energy at Meta, added in the release.

EDPR operates 61 wind farms, 29 solar parks and four energy storage sites across North America. Its other customers include other tech companies like Amazon and Microsoft.

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