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.

From Your Site Articles

Ace Green Recycling has secured a deal that will supply 100 percent of its phase one recycling capacity at its forthcoming Texas flagship facility. Photo courtesy Ace Green Recycling.

Houston battery recycling company signs 15-year deal to supply Texas flagship facility

green team

Houston- and Singapore-headquartered Ace Green Recycling, a provider of sustainable battery recycling technology solutions, has secured a 15-year battery material supply agreement with Miami-based OM Commodities.

The global commodities trading firm will supply Ace with at least 30,000 metric tons of lead scrap annually, which the company expects to recycle at its planned flagship facility in Texas. Production is expected to commence in 2026.

"We believe that Ace's future Texas facility is poised to play a key role in addressing many of the current challenges in the lead industry in the U.S., while helping the country meet the growing domestic demand for valuable battery materials," Nishchay Chadha, CEO and co-founder of Ace, said in a news release. "This agreement with OM Commodities will provide us with enough supply to support our Texas facility during all of its current planned phases, enabling us to achieve optimal efficiencies as we deploy our solutions in the U.S. market. With OM Commodities being a U.S.-based leader in metals doing business across the Americas and Asia with a specialty in lead batteries, we look forward to leveraging their expertise in the space as we advance our scale-up efforts."

The feedstock will be sufficient to cover 100 percent of Ace's phase one recycling capacity at the Texas facility, according to the statement. The companies are also discussing future lithium battery recycling collaborations.

"Ace is a true pioneer when it comes to providing an environmentally friendly and economically superior solution to recycle valuable material from lead scrap," Yiannis Dumas, president of OM Commodities, added in the news release. "We look forward to supporting Ace with lead feedstock as they scale up their operations in Texas and helping create a more circular and sustainable battery materials supply chain in the U.S."

Additionally, ACE shared that it is expected to close a merger with Athena Technology Acquisition Corp. II (NYSE: ATEK) in the second half of 2025, after which Ace will become a publicly traded company on the Nasdaq Stock Market under the ticker symbol "AGXI."

"As we continue to scale our lead and lithium battery recycling technologies to help support the markets for both internal combustion engines and electric vehicles, we expect that our upcoming listing will be a key accelerator of growth for Ace,” Chada said.

Ad Placement 300x100

Ad Placement 300x600

CultureMap Emails are Awesome

Property Showcase

Houston climatech startup closes $5M seed round to scale copper alternative

seeing green

Houston-based material science and climatech startup DexMat has closed a $5 million seed round.

The round was led by non sibi ventures, with participation from Governance Partners, Tailwind Futures, BetterWay, Capital Factory and other investors. The company additionally announced that it has secured $3 million of non-dilutive funding.

DexMat plans to use the recent round to commercially scale Galvorn, its carbon-based conductive fiber. The high-performance copper alternative, originally developed at Rice University, is made from carbon nanotube (CNT) fibers, which are less energy- and CO2-intensive to produce.

The company says it will grow its technical and commercial teams and advance pilot-scale production to meet demand from new and existing customers in aerospace, defense and manufacturing industries.

"We’re seeing clear customer pull, particularly in wire and cable applications, as manufacturers look for conductive materials that are less dense, more durable, and resilient at scale,” Bryan Guido Hassin, CEO of DexMat, said in a news release. “This funding allows us to meet near-term demand and expand production capabilities in response to evolving supply-chain constraints."

The recent funding comes after a year of impressive growth. According to the news release, DexMat more than doubled its production and sales of Galvorn in 2025 compared to the previous year.

“We consistently hear the same message from customers: the material performs really well, and they need more of it at a lower cost,” Dmitri Tsentalovich, co-founder and CTO of DexMat, added in the release. “This round supports the production scale-up and cost reductions required to move Galvorn into broader commercial use.”

DexMat raised $3 million in funding in a round led by Shell Ventures in 2023. The company reports a 20-fold increase in capacity since its pre-seed round, along with a 96 percent reduction in production costs.

DexMat's technology was originally developed in the Rice University lab of co-founder Matteo Pasquali, who also serves as director of Rice’s Carbon Hub. According to previous reports, the company was built on over $20 million in non-dilutive funding—including grants from the Air Force Research Laboratory, Air Force Office of Scientific Research, U.S. Department of Energy, NASA, Advanced Functional Fabrics of America and the National Science Foundation—with Rice University included in the list of original investors.

Here are 5 must-attend Houston energy events for February 2026

Mark Your Calendar

Editor's note: The second half of February is buzzing with must-attend events for those in the Houston energy sector. We've rounded up a host of events to put on your calendar for the month, with topics ranging from AI in energy to emissions management for a sustainable future. Get the details below, and register now.

Feb. 18-20 — NAPE Summit Week 2026

NAPE is the energy industry’s marketplace for the buying, selling, and trading of prospects and producing properties. NAPE brings together all industry disciplines and companies of all sizes, and in 2026 it will introduce three new hubs — offshore, data centers, and critical minerals — for more insights, access, and networking opportunities. The event includes a summit, exhibition, and more.

This event begins Feb. 18 at George R. Brown Convention Center. Register here.

Feb. 23-25 — AI in Energy Summit

The third annual AI in Energy Summit will bring together 200 senior leaders from the utilities, oil and gas, power generation, and renewables sectors for three days of conversation in Houston, the heart of energy innovation. Attendees will hear directly from operators who’ve taken AI projects from proof of concept to full deployment; learn how make data AI-ready and align AI with business goals; and discover what’s working in GenAI, ML Ops, Agentic AI, and more.

This event begins Feb. 23 at Norris Conference Center. Register here.

Feb. 24-26 — 2026 Energy HPC & AI Conference

The 2026 Energy HPC & AI Conference marks the 19th year for the Ken Kennedy Institute to convene experts from the energy industry, academia, and national labs to share breakthroughs for HPC and AI technologies. The conference returns to Houston with engaging speaker sessions, a technical talk program, networking receptions, add-on workshops, and more.

This event begins Feb. 24 at Rice University's BRC. Register here.

Feb. 25-26 — Energy Emissions Management Conference

The fifth annual Energy Emissions Management Conference is the premier gathering for energy leaders who are committed to staying ahead of the rapidly evolving emissions landscape. The conference aims to foster collaboration, drive technological innovation, and strengthen transparency, supporting organizations in meeting their regulatory obligations and sustainability goals.

This event begins Feb. 25 at Hilton Houston Westchase. Register here.

Feb. 26 — February Transition on Tap

Mix and mingle at Greentown Labs' first Transition on Tap event of the year. Meet the accelerator's newest startup members, who are working on innovations ranging from methane capture to emissions-free manufacturing processes to carbon management.

This event begins at 5:30 pm on Feb. 26 at Greentown Labs Houston. Register here.

Syzygy inks long-term offtake agreement for first commercial SAF plant

fuel deal

Houston-based Syzygy Plasmonics has secured a six-year official offtake agreement for the entire production volume of its first commercial-scale biogas-to-sustainable aviation fuel project in Uruguay, known as NovaSAF-1.

SP Developments Uruguay S.A., a subsidiary of Syzygy, entered into the agreement with Singapore-based commodity company Trafigura, according to a news release. There is also an option for Trafigura to purchase additional volumes from future Syzygy projects.

The first deliveries from the landmark SAF facility are expected in 2028.

“This agreement marks a critical step in our journey toward commercial-scale impact and disrupting the SAF market,” Trevor Best, CEO of Syzygy Plasmonics, said in the news release. “With a signed offtake agreement from a global leader like Trafigura, and after having successfully completed FEED engineering in December, we're now ready to secure financing for the construction of NovaSAF-1 and move our technology from potential into production."

The NovaSAF-1 project will be located in Durazno, Uruguay. The facility will be the world's first electrified biogas-to-SAF facility producing renewable and advanced compliant SAF. Syzygy estimates that the project will produce over 350,000 gallons of SAF annually. The facility is expected to produce SAF with at least an 80 percent reduction in carbon intensity compared to Jet A fuel.

It’s backed by Uruguay’s largest dairy and agri-energy operations, Estancias del Lago. It will also work with Houston-based Velocys, which will provide Fischer-Tropsch technology for the project. Fischer-Tropsch technology converts synthesis gas into liquid hydrocarbons, which is key for producing synthetic fuels like SAF.

View All Listings

ENERGYCAPITALHTX EMAILS ARE AWESOME