FREE4LIB Research Shows a Low-Energy Way to Restore EV Battery Material

As electric vehicles grow in number, so does the need to recycle their batteries in a smarter and more sustainable way. Instead of melting batteries down or using large amounts of chemicals to extract metals, researchers from FREE4LIB partners CARTIF and IREC tested a method that repairs used battery materials so they can be reused directly.

The study, published on February 2025, focused on NMC (nickel, manganese, cobalt) cathodes from real EV battery packs. These cathodes are widely used in electric vehicles and contain valuable materials.

Key findings

• Lithium can be successfully restored. Using a controlled electrochemical process in a simple water-based lithium sulfate solution, researchers were able to bring the lithium content of degraded cathodes close to their original level.

• Low energy use. The method operates at relatively low temperatures and avoids high-temperature smelting or large volumes of strong acids, meaning lower energy demand and fewer emissions.

• Material structure largely recovered. After a short heat treatment, the regenerated cathodes regained their layered structure and particle integrity, indicating they could be reused to make new battery materials.

• Process conditions are important. Stirring the electrolyte and using moderate heat improved the rate of lithium insertion, while lithium hydroxide solutions caused corrosion of aluminium current collectors and were less suitable.

Why this matters

NMC materials are among the most common cathodes in electric vehicles today. Finding efficient ways to restore them helps reduce the need for new raw materials and cuts the environmental footprint of battery production.

This research supports FREE4LIB’s goal of developing practical, low-impact recycling solutions. By focusing on direct regeneration rather than full material breakdown, the work contributes to closing the loop in Europe’s battery value chain ; keeping valuable materials in use longer while lowering energy consumption and environmental impact.

This work was carried out by CARTIF and IREC in the laboratory during the first two years of the project, and optimised in its final year.

Read the full publication: here.