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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How Corrolytics is tackling industrial corrosion and cutting emissions

now streaming

Corrosion is not something most people think about, but for Houston's industrial backbone pipelines, refineries, chemical plants, and water infrastructure, it is a silent and costly threat. Replacing damaged steel and overusing chemicals adds hundreds of millions of tons of carbon emissions every year. Despite the scale of the problem, corrosion detection has barely changed in decades.

In a recent episode of the Energy Tech Startups Podcast, Anwar Sadek, founder and CEO of Corrolytics, explained why the traditional approach is not working and how his team is delivering real-time visibility into one of the most overlooked challenges in the energy transition.

From Lab Insight to Industrial Breakthrough

Anwar began as a researcher studying how metals degrade and how microbes accelerate corrosion. He quickly noticed a major gap. Companies could detect the presence of microorganisms, but they could not tell whether those microbes were actually causing corrosion or how quickly the damage was happening. Most tests required shipping samples to a lab and waiting months for results, long after conditions inside the asset had changed.

That gap inspired Corrolytics' breakthrough. The company developed a portable, real-time electrochemical test that measures microbial corrosion activity directly from fluid samples. No invasive probes. No complex lab work. Just the immediate data operators can act on.

“It is like switching from film to digital photography,” Anwar says. “What used to take months now takes a couple of hours.”

Why Corrosion Matters in Houston's Energy Transition

Houston's energy transition is a blend of innovation and practicality. While the world builds new low-carbon systems, the region still depends on existing industrial infrastructure. Keeping those assets safe, efficient, and emission-conscious is essential.

This is where Corrolytics fits in. Every leak prevented, every pipeline protected, and every unnecessary gallon of biocide avoided reduces emissions and improves operational safety. The company is already seeing interest across oil and gas, petrochemicals, water and wastewater treatment, HVAC, industrial cooling, and biofuels. If fluids move through metal, microbial corrosion can occur, and Corrolytics can detect it.

Because microbes evolve quickly, slow testing methods simply cannot keep up. “By the time a company gets lab results, the environment has changed completely,” Anwar explains. “You cannot manage what you cannot measure.”

A Scientist Steps Into the CEO Role

Anwar did not plan to become a CEO. But through the National Science Foundation's ICorps program, he interviewed more than 300 industry stakeholders. Over 95 percent cited microbial corrosion as a major issue with no effective tool to address it. That validation pushed him to transform his research into a product.

Since then, Corrolytics has moved from prototype to real-world pilots in Brazil and Houston, with early partners already using the technology and some preparing to invest. Along the way, Anwar learned to lead teams, speak the language of industry, and guide the company through challenges. “When things go wrong, and they do, it is the CEO's job to steady the team,” he says.

Why Houston

Relocating to Houston accelerated everything. Customers, partners, advisors, and manufacturing talent are all here. For industrial and energy tech startups, Houston offers an ecosystem built for scale.

What's Next

Corrolytics is preparing for broader pilots, commercial partnerships, and team growth as it continues its fundraising efforts. For anyone focused on asset integrity, emissions reduction, or industrial innovation, this is a company to watch.

Listen to the full conversation with Anwar Sadek on the Energy Tech Startups Podcast to learn more:

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Energy Tech Startups Podcast is hosted by Jason Ethier and Nada Ahmed. It delves into Houston's pivotal role in the energy transition, spotlighting entrepreneurs and industry leaders shaping a low-carbon future.

Investors close partial acquisition of Phillips 66 subsidiary with growing EV network

M&A activity

Energy Equation Partners, a London-based investment firm focused on clean energy companies, and New York-based Stonepeak have completed the acquisition of a 65 percent interest in JET Tankstellen Deutschland GmbH, a subsidiary of Houston oil and gas giant Phillips 66.

JET is one of the largest and most popular fuel retailers in Germany and Austria with a rapidly growing EV charging network, according to a news release. It also operates approximately 970 service stations, convenience stores and car washes.

“We are delighted to complete this acquisition and to partner with Stonepeak and Phillips 66 to take JET to the next level,” Javed Ahmed, managing partner of Energy Equation Partners, said in a news release. “This investment reflects EEP’s commitment to investing in established players in the energy sector who have the potential to make a meaningful impact on the energy transition, and we are excited to work alongside the entire JET team, including its dedicated service station operators, to realize this vision.”

The deal values JET at approximately $2.8 billion. Phillips 66 will retain a 35 percent non-operated interest in JET and received about $1.6 billion in pre-tax proceeds.

“Under Phillips 66’s ownership, JET has grown into one of the largest fuel retailers in Germany and Austria," Anthony Borreca, senior managing director and co-head of energy at Stonepeak, added in a news release. "We are excited to join forces with them, as well as Javed and the EEP team, who have long-standing experience investing in and operating retail fuel distribution and logistics globally, to support the next phase of JET’s growth.”

6 must-attend Houston energy events in December 2025

Event Guide

Editor's note: The year is coming to a close, but there are still exciting energy events to attend in Houston this month. Mark your calendar now for pitch days, seminars, networking, and Reuters Energy LIVE 2025.

Dec. 4 — Resiliency & Adaptation Sector Pitch Day

Join innovators, industry leaders, investors, and policymakers as they explore breakthrough climate and energy technologies at Greentown Labs' latest installment of its Sector Pitch Day series, focused on resiliency and adaptation. Hear from Adrian Trömel, Chief Innovation Officer at Rice University; Eric Willman, Executive Director of the Rice WaTER Institute; pitches from 10 Greentown startups; and more.

This event is Thursday, Dec. 4, from 1-3:30 p.m. at the Ion. The Ion Holiday Block Party follows. Register here.

Dec. 8 — Pumps & Pipes Annual Event 2025

The annual gathering brings together cross-industry leaders in aerospace, energy and medicine for engaging discussions and networking opportunities. Connor Grennan, Chief AI Architect at the NYU Stern School of Business, will present this year's keynote address, "Practical Strategies to Increase Productivity." Other sessions will feature leaders from Cena Research Institute, NASA Ames Research Center, ExxonMobil, Southwest Airlines, and more.

This event is Monday, Dec. 8, from 8 a.m.-5 p.m., at TMC Helix Park. Register here.

Dec. 9 — Energy in Action Seminar

The Energy Transition Institute hosts a monthly Energy in Action Seminar focused on the digitization of the global energy transition. This month's topic is "Exploring AI’s Impact on the Fuels & Petrochemicals Industry," featuring speaker Leo Chiang, Senior Director of Corporate Technology at The Lubrizol Corporation. The event includes a one-hour talk followed by an hour of networking.

This event is Dec. 9 from 4-6 pm at the University of Houston.

Dec. 9-10 — Energy LIVE 2025

Energy LIVE is Reuters Events' flagship conference and expo that brings the full energy ecosystem together under one roof in Houston to solve the industry's most urgent commercial and operational challenges. The event will feature 3,000-plus senior executives across three strategic stages, a showcase of 75-plus exhibitors, and six strategic content pillars.

This event is Dec. 9-10 at NRG Park. Register here.

Dec. 11-12 — Fundamentals of The Texas ERCOT Electric Power Market

This two-day seminar provides a comprehensive overview of the structure, function, and current status of the Texas ERCOT ISO. Attendees will gain an understanding of the dynamic Texas wholesale and retail competitive markets, and learn how these markets interface with ERCOT ISO energy auctions and ISO operations. This two-day event will also address the rapidly expanding new market opportunities in Texas renewables, distributed generation, demand response, and demand side management, and more.

This event is Dec. 11-12 at the Courtyard Marriott Houston near the Galleria. Register here.

Dec. 9-11 — AST Conference & Trade Show

The 18th Annual National Aboveground Storage Tank (AST) Conference & Trade Show is the premier event for professionals in storage tank and terminal operations. Join industry leaders and experts for a three-day conference providing regulatory updates, technical insights, hands-on learning, and networking opportunities.

This event is Dec. 9-12 at The Woodlands Waterway Marriott. Register here.

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