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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Air Liquide and Hyundai ink partnership to scale hydrogen economy

green team

Air Liquide, which maintains its U.S. headquartered in Houston, and South Korea-based Hyundai Motor Group are expanding their strategic partnership to accelerate the growth of the global hydrogen ecosystem.

The renewal of the companies’ Memorandum of Understanding (MoU) was announced at the Hydrogen Council CEO Summit in Seoul last week. Together, the companies will work to scale hydrogen production, storage, transportation and utilization across Europe, Korea and the United States with a concentration on heavy-duty transport, logistics and public transportation.

Hyundai hopes Air Liquide's technical expertise will help contribute to more sustainable energy and carbon neutrality.

The companies plan to develop hydrogen refueling networks and storage capacity that can meet growing demands. They also plan to commercialize fuel cell electric vehicles (FCEVs) for diverse applications like public transportation, logistics fleets and ports.

"We are delighted to strengthen our partnership with Hyundai Motor Group,” Armelle Levieux, vice president of innovation, electronics and hydrogen at Air Liquide, said in a news release. “Collaborations like this between leaders across the value chain are essential to building the hydrogen economy.”

The partnership has already shown strong progress in South Korea, according to the companies, with Hyundai rolling out more than 2,000 hydrogen buses and 37,000 passenger fuel cell vehicles, with more expected by 2026. Additionally, Air Liquide has boosted supply capabilities in the region with the new state-of-the-art high-pressure hydrogen filling center, Lotte-Air Liquide Ener’Hy, in Daesan, an industrial hub near Seoul.

Air Liquide and Hyundai previously signed an MoU in 2018, along with other major South Korean players, agreeing to grow the hydrogen economy.

Hazardous waste company with Houston presence to make $3B acquisition

big deal

Veolia, a Boston-based company with major operations in Texas, is purchasing hazardous-waste company Clean Earth from Enviri as part of a $3 billion deal.

Veolia is a private water operator, technology provider and hazardous waste and pollution treatment company that operates a large hazardous waste treatment and incineration facility in Port Arthur. Hazardous waste treatment is a growing sector as the clean energy, semiconductor manufacturing, healthcare and pharmaceutical industries generate high levels of waste that need to be handled safely.

Acquiring Clean Earth’s 82 facilities, which include 19 EPA-permitted sites, will expand Veolia’s reach into 10 new states and will position the company as the second-largest hazardous waste operator in the U.S., according to a news release. The deal is Veolia’s sixth and largest North American acquisition of 2025.

“(The acquisition) allows us to unlock the full value potential of our U.S. hazardous waste activities and to double our size on this critical, fast-growing sector, creating a No. 2 player,” Estelle Brachlianoff, CEO of Veolia, said in a news release. “We reinforce our global capacities in hazardous waste and further increase our international footprint.”

Veolia’s Port Arthur facility specializes in servicing generators with large-volume waste treatment requirements.

The transaction is expected to close mid-2026. Veolia hopes the increased exposure into industries such as retail and healthcare will help to offer a full range of environmental services across the U.S.

“This continued transformation of our portfolio enhances the growth profile and strength of our group, uniquely positioned to tackle the sustained demand for environmental security,” Brachlianoff added in the release.

Reliant partners to expand Texas virtual power plant and home battery use

energy incentives

Houston’s Reliant and San Francisco tech company GoodLeap are teaming up to bolster residential battery participation and accelerate the growth of NRG’s virtual power plant (VPP) network in Texas.

Through the new partnership, eligible Reliant customers can either lease a battery or enter into a power purchase agreement with GoodLeap through its GoodGrid program, which incentivises users by offering monthly performance-based rewards for contributing stored power to the grid. Through the Reliant GoodLeap VPP Battery Program, customers will start earning $40 per month in rewards from GoodLeap.

“These incentives highlight our commitment to making homeowner battery adoption more accessible, effectively offsetting the cost of the battery and making the upgrade a no-cost addition to their homes,” Dan Lotano, COO at GoodLeap, said in a news release.“We’re proud to work with NRG to unlock the next frontier in distributed energy in Texas. This marks an important step in GoodLeap reaching our nationwide goal of 1.5 GW of managed distributed energy over the next five years.”

Other features of the program include power outage plans, with battery reserves set aside for outage events. The plan also intelligently manages the battery without homeowner interaction.

The partnership comes as Reliant’s parent company, NRG, continues to scale its VPP program. Last year, NRG partnered with California-based Renew Home to distribute hundreds of thousands of VPP-enabled smart thermostats by 2035 in an effort to help households manage and lower their energy costs.

“We started building our VPP with smart thermostats across Texas, and now this partnership with GoodLeap brings home battery storage into our platform,” Mark Parsons, senior vice president and head of Texas energy at NRG, said in a the release. “Each time we add new devices, we’re enabling Texans to unlock new value from their homes, earn rewards and help build a more resilient grid for everyone. This is about giving customers the opportunity to actively participate in the energy transition and receive tangible benefits for themselves and their communities.

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