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Houston scientists unveil faster, low-energy method to recycle lithium-ion batteries

Battery breakthrough

Simon M. King, a Rice University sophomore, served as the first author on a recent study of a new process for recycling lithium-ion batteries. Photo courtesy Rice

Rice University researchers have uncovered a more energy-efficient and faster way to recycle critical minerals from used lithium-ion batteries.

Traditional methods rely on high heat, long processing times and harsh chemicals to recover a small fraction of critical materials from batteries used in everything from smartphones to electric vehicles. However, the team from Rice's Department of Materials Science and Nanoengineering developed a process that uses a water-based solution containing amino chlorides to extract more metals in less time

The team published the findings in a recent edition of the scientific journal Small.

Simon King, a sophomore studying chemical and biomolecular engineering who completed this work as a summer research fellow at the Rice Advanced Materials Institute, served as first author of the study. He worked with corresponding authors Pulickel Ajayan, the Benjamin M. and Mary Greenwood Anderson Professor of Engineering, and Sohini Bhattacharyya, a research scientist in Ajayan’s lab.

By using a hydroxylammonium chloride (HACI) solution, the team achieved roughly 65 percent extraction of key battery metals in just one minute at room temperature, according to the study. The efficiencies grew to roughly 75 percent for several metals under longer processing times.

“We were surprised by just how fast the reaction occurs, especially without the involvement of high temperatures,” King said in a news release. “Within the first minute, we’re already seeing the majority of the metal extraction take place.”

By not requiring high temperatures or long reaction times, Rice predicts the process could have a major impact on cost and the environmental impact of lithium battery recycling. Additionally, the water-based HACI solution makes waste handling easier and lowers certain environmental risks.

In addition to extracting the materials, the team went on to demonstrate that the recovered metals could be recycled and reprocessed into new battery materials.

“A big advantage of this system is that it works under relatively mild conditions,” Ajayan added in the release. “That opens the door to more sustainable and scalable recycling technologies.”

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Chevron U.S.A. has acquired 125,000 acres in Northeast Texas and southwest Arkansas that contain a high amount of lithium. Photo via Getty Images.

Chevron enters lithium market with Texas land acquisition

to market

Chevron U.S.A., a subsidiary of Houston-based energy company Chevron, has taken its first big step toward establishing a commercial-scale lithium business.

Chevron acquired leaseholds totaling about 125,000 acres in Northeast Texas and southwest Arkansas from TerraVolta Resources and East Texas Natural Resources. The acreage contains a high amount of lithium, which Chevron plans to extract from brines produced from the subsurface.

Lithium-ion batteries are used in an array of technologies, such as smartwatches, e-bikes, pacemakers, and batteries for electric vehicles, according to Chevron. The International Energy Agency estimates lithium demand could grow more than 400 percent by 2040.

“This acquisition represents a strategic investment to support energy manufacturing and expand U.S.-based critical mineral supplies,” Jeff Gustavson, president of Chevron New Energies, said in a news release. “Establishing domestic and resilient lithium supply chains is essential not only to maintaining U.S. energy leadership but also to meeting the growing demand from customers.”

Rania Yacoub, corporate business development manager at Chevron New Energies, said that amid heightening demand, lithium is “one of the world’s most sought-after natural resources.”

“Chevron is looking to help meet that demand and drive U.S. energy competitiveness by sourcing lithium domestically,” Yacoub said.

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.

The Rice team's process is up to 10 times more effective than existing lithium-ion battery recycling. Photo by Gustavo Raskosky/Rice University

Houston scientists discover breakthrough process for lithium-ion battery recycling

researching for the future

With the rise of electric vehicles, every ounce of lithium in lithium-ion batteries is precious. A team of scientists from Rice University has figured out a way to retrieve as much as 50 percent of the material in used battery cathodes in as little as 30 seconds.

Researchers at Rice University’s Nanomaterials Laboratory led by Department of Materials Science and NanoEngineering Chair Pulickel Ajayan released the findings a new study published in Advanced Functional Materials. Their work shows that the process overcomes a “bottleneck” in lithium-ion battery recycling technology. The researchers described a “rapid, efficient and environmentally friendly method for selective lithium recovery using microwave radiation and a readily biodegradable solvent,” according to a news release.

Past recycling methods have involved harsh acids, and alternative eco-friendly solvents like deep eutectic solvents (DESs) at times have not been as efficient and economically viable. Current recycling methods recover less than 5 percent of lithium, which is due to contamination and loss during the process.

In order to leach other metals like cobalt or nickel, both the choline chloride and the ethylene glycol have to be involved in the process, according to the researchers at Rice. The researchers submerged the battery waste material in the solvent and blasted it with microwave radiation since they knew that of the two substances only choline chloride is good at absorbing microwaves.

Microwave-assisted heating can achieve similar efficiencies like traditional oil bath heating almost 100 times faster. Using the microwave-based process, Rice found that it took 15 minutes to leach 87 percent of the lithium, which differs from the 12 hours needed to obtain the same recovery rate via oil bath heating.

“This method not only enhances the recovery rate but also minimizes environmental impact, which makes it a promising step toward deploying DES-based recycling systems at scale for selective metal recovery,” Ajayan says in the release.

Due to rise in EV production, the lithium-ion battery global market is expected to grow by over 23 percent in the next eight years, and was previously valued at over $65 billion in 2023.

“We’ve seen a colossal growth in LIB use in recent years, which inevitably raises concerns as to the availability of critical metals like lithium, cobalt and nickel that are used in the cathodes,” the study's co-author, Sohini Bhattacharyya, adds. “It’s therefore really important to recycle spent LIBs to recover these metals.”

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ExxonMobil secures approval for $5B East Texas carbon capture project

ccs expansion

Spring-based ExxonMobil has won approval from the Texas Railroad Commission for a $5 billion carbon capture and storage project in East Texas.

Dominic Genetti, senior vice president of CCS at ExxonMobil, told The Financial Times, which broke the news, that the Railroad Commission’s action is a “major milestone” that lets the company keep expanding along the Gulf Coast. In a 2-1 vote, commissioners authorized a carbon sequestration permit for the project.

“The Railroad Commission clearly recognizes the important role carbon capture and storage can play in meeting growing global demand for lower-carbon products while supporting new jobs and economic growth,” Genetti said.

The U.S. Environmental Protection Agency (EPA) approved ExxonMobil’s Rose CCS project last year.

The project will enable the company to inject about 53 metric tons of industrial customers’ carbon emissions into three underground wells it drilled in the Beaumont-Port Arthur area. Over a 13-year period, ExxonMobil plans to inject about 4 million metric tons per year into the Fleming and Upper Frio rock formations, according to Carbon Herald.

ExxonMobil says it owns the world’s first and largest CCS system, comprising 1,300 miles of CO2 pipeline and secure storage sites. Seventy percent of the pipelines are along the Gulf Coast.

The company ramped up its CCS business in 2023 with the $4.9 billion purchase of Denbury, which owned about 1,000 miles of CO2 pipelines.

“Our expertise, combined with Denbury’s talent and CO2 pipeline network, expands our low-carbon leadership and best positions us to meet the decarbonization needs of industrial customers while also reducing emissions in our own operations,” ExxonMobil Chairman and CEO Darren Woods said when the deal closed.

In January, Genetti wrote in a post on ExxonMobil’s website that the company is committed to CCS “for the long haul.”

“CCS is not new technology, but it’s flown relatively under the radar compared with the attention that production of hydrocarbons commands,” he wrote. “Now, as the world becomes more aware of the need to reduce emissions, CCS finally has a brighter spotlight and a broader runway to scale up.”

The company also announced this week that it has begun CCS operations at a direct reduced iron facility in Convent, Louisiana. The project will capture, transport and store up to 800,000 metric tons of CO2 per year, according to the company.

Houston’s power future: The role of energy efficiency and demand response

The View from HETI

In Houston, industrial expansion, advanced manufacturing, data centers, AI, electrification, and population growth are all increasing demand for power across the region. At the same time, the infrastructure needed to support that growth, from generation and transmission to distribution and storage, takes significant time and investment to plan and build.

This growing power demand creates a near-term challenge: how can the region support new investment while major grid projects are planned and built?

A new report from the Houston Energy Transition Initiative, “Role of Efficiency & Demand Response to Meet Near-Term Regional Power Demand”, examines how Houston can get more from the grid it has today. Its central finding: energy efficiency (EE) and demand response (DE) can create measurable grid “headroom” while new major infrastructure projects are being planned, financed, permitted and built.

Explore the key takeaways from the report:

Houston’s power challenge affects economic growth

Houston’s ability to attract industrial investment increasingly depends on reliable, affordable power. ERCOT and MISO Texas project major load growth through 2030 and 2035 from industrial development, data centers, AI, advanced manufacturing and electrification.

Efficiency and demand response can lower peak demand and help manage local grid constraints that could slow growth.

EE and DE are different tools, and Houston needs both

Energy efficiency creates lasting reductions in electricity use through equipment upgrades, building improvements and changes in operations. Demand response lets customers temporarily reduce or shift power use based on grid conditions, incentives or market signals.

Texas programs show measurable results

In 2024, Texas investor-owned utility programs delivered about 609 MW of evaluated demand reduction and 603 GWh of annual energy savings. The report puts the lifetime cost of saved energy at about $0.02 per kWh.
CenterPoint Energy accounted for more than 40% of ERCOT investor-owned utilities’ total demand reduction and energy savings. It achieved about 236 MW of peak demand reduction and 229 GWh of energy savings, above goals of 66 MW and 116 GWh.

Entergy Texas also achieved significantly more demand reduction and energy savings than its 2024 program year goals, with a reported 24 MW of peak demand reduction against a goal of 17 MW and 43 GWh of energy savings against a goal of 30 GWh.

Large power users can add flexibility

Data centers, industrial facilities and advanced manufacturers may be able to shift noncritical work, adjust cooling, use on-site resources or briefly cut consumption.

The report states that verified demand savings, flexible loads and behind-the-meter resilience could help reduce interconnection risk and support more cost-effective growth.

Technology can expand options

Storage, smart controls and energy management systems can work with efficiency and demand response. Smaller loads can also be combined across commercial buildings, multifamily developments and homes.

For Houston, these tools do not replace new generation, transmission, distribution or storage. They can help the region use existing infrastructure more effectively while new capacity is built, supporting reliable, affordable power and continued economic growth.

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This article originally appeared on the Greater Houston Partnership's Houston Energy Transition Initiative blog. HETI exists to support Houston's future as an energy leader. For more information about the Houston Energy Transition Initiative, visit htxenergytransition.org. Download your copy of Role of Efficiency & Demand Response to Meet Near-Term Regional Power Demand to learn more.

Clean energy leaders taking the stage at Houston Energy and Climate Week

expert voices

Some of the biggest names in the clean energy scene will be sharing their expertise in Houston this week.

From leaders fresh off one of the industry's biggest IPOs to local organizers, here's who's speaking at promising panels and anchor events during Houston Energy and Climate Week—taking place now through Sept. 18. Visit each event's website for a full lineup.

Read more about Houston Energy and Climate Week and its programming in Energy Capital's event preview. Or learn more about the startups pitching at events throughout the week here.

Energy Solutions in a New Era Hosted by JERA & Mitsubishi Heavy Industries — Sept. 15 at the Ion

  • Mary Dhillon, strategy manager at Fervo Energy
  • Ricky Sakai, SVP of investment & business development at Mitsubishi Heavy Industries America
  • Daniel Padilla, strategy & business development lead at Emerald AI
  • Adrian Trömel, chief innovation officer / interim vice president for innovation at Rice University (moderator)
  • Shigeki Uchihashi, VP of strategy & corporate venturing at JERA Americas

Cypher Pilotathon and Startup Showcase — Sept. 15 at POST Houston

  • Nada Ahmed, co-founder and CRO of Energytech Cypher
  • Taylor Chapman, investment principal at New Climate Ventures
  • Jason Ethier, co-founder and CEO of Energytech Cypher
  • Sean Kelly, CEO of Amperon
  • Ionel Nechiti, investment director for Aramco Ventures
  • Hema Prapoo, global energy industry leader from Microsoft
  • Ishan Rao, VP of commercial at Syzygy Plasmonics

Greentown Climatetech Summit — Sept. 16 at Greentown Labs

  • Arne Ballantine, co-founder of Ohmium International
  • David Baldwin, partner at SCF Partners
  • Christopher Hanson, former chair of the U.S. Nuclear Regulatory Commission
  • Tim Latimer, CEO and co-founder of Fervo Energy
  • Georgina Campbell Flatter, CEO of Greentown Labs
  • Nicolaus Radford, CEO and co-founder of Persona AI
  • Prag Mishra, chief AI officer at Armada
  • Jeremy Pitts, managing director at Activate
  • Bobby Gallagher, CEO, CTO and co-founder of Deployable Energy
  • Jason Wells, chair, president and CEO of CenterPoint Energy
  • Eliecer Viamontes, CEO of Entergy Texas

Rice Alliance Energy Tech Venture Forum — Sept. 17 at Rice University’s Jones Graduate School of Business

  • Laurent Alteirac, enabling technology development manager at SLB
  • Kemal Anbarci, managing executive and general manager of venture capital at Chevron Technology Ventures
  • Sameer Bandhu, managing director of ventures and licensing at GE Vernova
  • Brad Burke, former associate vice president at Rice Office of Innovation and former executive director of Rice Alliance for Technology and Entrepreneurship at Rice University (moderator)
  • Andres Cabada, managing director at Halliburton Labs
  • Quennie Co, managing partner at Shell Ventures
  • Rob Crane, technology scouting & venturing manager at ExxonMobil
  • Ira Ehrenpreis, founder and managing partner at DBL Partners
  • Menachem Elimelech, director of Rice Center for Membrane Excellence (RiCeME) at Rice University
  • Brian Iversen, founder & managing partner at Cimbria Capital
  • Dustin Kinder, CEO of Maverick Water Group
  • Megan Lund, lead of venturing strategy & strategic partnerships at Woodside Energy
  • Sean Maher, vice president of investor relations & chief economist at Phillips 66
  • Robert Mellors, SUPERHOT program director at ARPA-E
  • John (JR) Reale, interim associate vice president for industry and new ventures at Rice University and executive director of Rice Alliance for Technology and Entrepreneurship at Rice University
  • Chad Seely, SVP of regulatory policy, general counsel, chief compliance officer, and corporate secretary at ERCOT
  • David Sholl, executive vice president for research and professor of chemical & biomolecular engineering at Rice University
  • Jim Sledzik, managing director of strategic venturing, North America, at Aramco Ventures
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