The Growing Challenge of Li-ion Battery Waste

Lithium-ion batteries power everything from smartphones to EVs, but their short lifespan creates massive waste streams. Globally, spent LIBs are projected to exceed 11 million tons annually by 2030, with critical metals like lithium, cobalt, and nickel in high demand. In Singapore, EV registrations have climbed to over 10,000 in 2025, and with the Resource Sustainability Act's Extended Producer Responsibility (EPR) framework mandating battery take-back since 2023, recycling infrastructure is ramping up.

The city-state's lithium-ion battery recycling market was valued at around SGD 120 million in 2024 and is expected to grow rapidly, driven by policies like the Singapore Battery Consortium led by A*STAR. Yet, challenges persist: high energy costs, chemical waste, and low recovery rates from mixed cathode types. Singapore imports most raw materials, making local recycling vital for supply security and reducing import dependency.

• Singapore generated approximately 1,200 tons of battery waste in 2025, per NEA estimates.
• EV battery lifespan averages 8-10 years, meaning EOL volumes will peak post-2030.
• Traditional recycling recovers only 50-70% of lithium, often with toxic byproducts.

This NUS breakthrough positions Singapore as a leader in addressing these issues through homegrown research.

Unpacking the Self-Driven Recycling Technology

The core innovation is a redox-targeting flow cell that pairs two common spent cathode types: LiFePO₄ (anode) and layered oxides like LiNi_0.8Co_0.1Mn_0.1O₂ (NCM811, cathode). Here's how it works step-by-step:

1. Feedstock Preparation: Spent black mass from dismantled batteries is slurried into anolyte (LiFePO₄) and catholyte (layered oxide).
2. Redox Leaching: At the anode, LiFePO₄ oxidizes to FePO₄, releasing Li⁺. At the cathode, layered oxide reduces, also freeing Li⁺. This self-driven process generates voltage (0.5-1V).
3. Lithium Migration: Li⁺ ions migrate across a membrane to the catholyte, achieving selective recovery.
4. Electricity Generation: The cell produces power, theoretically 246 MWh per 10,000 tons of black mass processed annually.
5. Closed Loop: Hydrogen looping regenerates base/acid electrolytes, eliminating net chemical input. CO₂ is captured at 1,066 tons/year.

This elegant design minimizes external energy needs, unlike pyrometallurgy (high temp smelting) or hydrometallurgy (acid leaching).

Key Results: High Efficiency and Green Byproducts

The NUS team demonstrated leaching efficiencies over 95% for Fe, Ni, Co, Mn, and Li from both cathode types. Regenerated materials matched fresh performance in coin cells, with capacities rivaling commercial benchmarks.

Bonus: The process captures CO₂ via carbonate formation and generates electricity, flipping recycling from cost center to value creator. Techno-economic analysis shows 30% lower costs and 50% less emissions than hydrometallurgy for 10,000 tons/year scale.

Outperforming Traditional Recycling Methods

Compare to pyrometallurgy (energy-intensive, lithium loss) and hydrometallurgy (chemical-heavy):

• Energy Use: Self-driven: near-zero external input vs. 5-10 MWh/ton for pyro.
• Chemical Consumption: Closed loop (zero net) vs. tons of acid/base per ton black mass.
• Yield: 95%+ multi-metal vs. selective recovery.
• Byproducts: Electricity + CO₂ capture vs. slag/wastewater.

In Singapore's context, where land/energy are scarce, this method scales efficiently, supporting the nation's 1,000+ e-waste points and EPR mandates.

Singapore's Strategic Push in Battery Research

A*STAR's Battery Centre and NUS labs are hubs for this work. Prof. Qing Wang's group has pioneered redox strategies since 2019, with prior patents on LIB recycling. Singapore's ecosystem includes startups like NEU Battery Materials (NUS spin-off, SGD 4M funded) and policies like the Green Plan 2030.

The Singapore Battery Consortium fosters industry-academia ties, while A*STAR's EV disassembly line aids R&D. With EV incentives (e.g., VES rebate up to SGD 45K), battery EOL management is key.

Implications for the EV Transition and Circular Economy

This tech secures critical metals (Singapore imports 100%), cuts mining emissions (50% of LIB footprint), and supports net-zero. For EVs, it enables second-life uses post-recycling. Globally, it models scalable green recycling amid 2030 shortages.

Stakeholders: Policymakers (EPR expansion), industry (cheaper materials), researchers (new flow cell paradigms).

Challenges, Future Outlook, and Opportunities

Scaling pilot to industrial needs optimization; mixed waste sorting remains hurdle. Future: Integrate with A*STAR testing, commercialize via startups. Singapore aims for regional hub.

Careers abound: Explore research jobs in battery tech or Singapore academic positions.

Photo by Louis Hansel on Unsplash

Joining Singapore's Battery Revolution

This NUS-A*STAR advance exemplifies Singapore's R&D prowess. For professionals, opportunities in sustainable materials abound. Check higher ed career advice, higher ed jobs, university jobs, and rate my professor for insights.