CO2 Lithium Battery Recycling Breakthrough: Chinese Scientists Develop Revolutionary Three-in-One Method

Chinese Breakthrough in CO2 Lithium Battery Recycling

In a significant advancement for sustainable energy, researchers from the Chinese Academy of Sciences (CAS) and Beijing Institute of Technology (BIT) have developed a groundbreaking three-in-one method for recycling lithium from spent batteries using only carbon dioxide (CO2) and water. This CO2 lithium battery recycling breakthrough achieves over 95% lithium recovery at room temperature, while simultaneously capturing CO2 and upcycling metal residues into catalysts for green hydrogen production. Published in Nature Communications on January 10, 2026, the study led by Yue Wang and colleagues addresses critical challenges in the electric vehicle (EV) battery lifecycle.

The innovation comes at a pivotal time as global lithium demand surges with EV adoption. By 2030, lithium needs are projected to quadruple, driven by battery requirements exceeding 4,700 gigawatt-hours annually. China, producing over 80% of the world's lithium-ion batteries, dominates recycling too, processing 3.6 million tonnes of scrap in 2025 alone. This method positions Chinese higher education institutions like BIT at the forefront of green materials science.

The Urgent Need for Better Battery Recycling

Lithium-ion batteries power everything from smartphones to EVs, but their short lifespan creates massive waste. By 2050, spent batteries could generate up to 381 million metric tonnes globally if unmanaged. Current recycling rates hover around 5% worldwide, with pyrometallurgical (high-heat smelting) and hydrometallurgical (acid leaching) methods dominating. Pyrometallurgy consumes vast energy and loses lithium, while hydrometallurgy produces toxic wastewater from sulfuric or hydrochloric acids.

China's battery recycling market reached 301,668 tonnes in 2025, up 7% year-on-year, but environmental concerns persist. The new process eliminates these issues, using abundant CO2—potentially from industrial flue gas—to form mild carbonic acid (H2CO3) with water, enabling selective lithium extraction without pollution.

How the Three-in-One Process Works Step by Step

The method integrates mechanochemistry with CO2-assisted leaching for efficiency. Here's the breakdown:

• Mechanochemical Activation: Spent cathodes (e.g., nickel-cobalt-manganese oxide, NCM) undergo high-energy ball milling at 600 rpm for 2 hours (20 min rotation, 10 min pause cycles). This induces lithium-transition metal (Li/TM) micro-segregation, creating a Li-rich amorphous surface layer (~20 nm thick) while disordering the crystal structure (up to 73% amorphous content).
• CO2 Leaching: The activated powder mixes with water under 0.5 MPa CO2 pressure at 25°C for 1 hour. CO2 forms H2CO3, selectively dissolving lithium via three pathways: soluble Li-rich phase dissolution, Li+/H+ ion exchange, and lattice Li acidic dissolution. Yields lithium bicarbonate (LiHCO3) solution (>95% recovery for NCM811).
• Upcycling and Purification: Residues become oxygen evolution reaction (OER) catalysts with oxygen vacancies and hydroxide surfaces. Leachate purifies via pH adjustment with LiOH, yielding battery-grade Li2CO3 (>98.5% purity) after thermal decomposition.

This closed-loop approach sequesters CO2 in solid Li2CO3, preventing emissions.

Lab Results: High Efficiency Across Battery Types

Tests on fresh and spent cathodes showed robust performance. Lithium leaching: 95.43% (NCM811), 91.56% (NCM622), 88.53% (NCM111), 93.13% (spent LTMO). Selectivity >94-99%, minimal TM loss (<1%). OER catalysts excelled: 322 mV overpotential at 10 mA/cm² (vs. 367 mV for Co3O4), Tafel slope 90 mV/dec, stable >200 hours.

Advanced tools like TOF-SIMS confirmed Li-rich surfaces post-milling, while XANES/EXAFS revealed Ni reduction and disordering mechanisms.Full paper here.

Environmental and Economic Wins Over Traditional Methods

• No toxic acids or high heat: Reduces energy use and wastewater.
• CO2 capture: Locks greenhouse gas in products.
• Upcycling: Turns waste into high-value OER catalysts for hydrogen electrolyzers.
• Cost-effective: Ambient conditions, simple reagents; scalable for industry.

Global LIB recycling market to hit $88B by 2030; China's dominance (80%) could accelerate with this tech.

Beijing Institute of Technology's Role in Innovation

BIT, a top Chinese engineering university, contributed key expertise via Li Li from its School of Materials Science & Engineering. BIT ranks high in materials science, fostering research in sustainable batteries. Collaborations with CAS's Institute of Process Engineering highlight China's higher ed strength in interdisciplinary green tech. Aspiring researchers can explore research jobs in battery materials at institutions like BIT.

China's Dominance in Battery Supply Chain

China controls 80% of global battery production and recycling, with firms like CATL achieving 99.6% metal recovery (non-CO2 method). This CO2 lithium battery recycling positions universities as innovation hubs amid lithium demand boom—projected 6,530 GWh batteries by 2050. Policies like the 14th Five-Year Plan boost recycling infrastructure.

Explore higher ed opportunities in China.

Challenges and Scalability Path Forward

Lab success is promising, but industrial hurdles include throughput and cost validation. Researchers note suitability for high-Ni cathodes (common in EVs). Pilot plants could integrate with CO2 sources like cement plants. Global adoption may face policy hurdles outside China.

Implications for Clean Energy Transition

This reduces mining pressure (China supplies 60% lithium), cuts CO2 emissions, and supports EV/grid storage. By 2030, recycled lithium could meet 10-12% demand. Enables circular economy, aligning with UN SDGs.

Photo by P C on Unsplash

Career Opportunities in Green Battery Research

The field booms: demand for materials scientists, chemists. BIT/CAS exemplify paths. Check higher ed research jobs, university jobs, or career advice for roles in sustainable tech. Rate your professors and connect with mentors.

For more on China's innovations, visit SCMP coverage or TechXplore.