Sandia National Laboratories' Battery Upcycling Cuts Energy Use

Scientists at Sandia National Laboratories have developed a process called BatterUP that upcycles spent lithium‑ion battery cathodes using microwave irradiation and ion‑exchange. The method exfoliates cathode material into nanosheets, allowing impurities to be removed and enabling flexible reformulation of the cathode composition while using far less energy and time than traditional pyrometallurgical or hydrometallurgical recycling. Clare Davis‑Wheeler Chin explained, “The layered structure of the cathode allows us the opportunity to use microwaves… to physically separate the layers into 5‑ to 10‑nm‑thick nanosheets that are stable for long periods.”

In parallel, Australian researchers have identified 316L stainless steel as an effective electrode for electrochemically recovering silver from end‑of‑life photovoltaic modules. Their tests achieved up to 93 % silver recovery and about 96 % Faradaic efficiency, with performance dependent on current density and copper contamination. The team noted, “Although silver represents only around 0.03 % of the weight of a complete PV module, it accounts for half of the material value.” Both advances aim to improve material recycling efficiency and reduce the long‑term lock‑up of valuable resources.