Scientists at Worcester Polytechnic Institute have developed a scalable method to recycle lithium-ion batteries that is both energy-efficient and environmentally friendly. Led by Professor Yan Wang, the team’s hydrometallurgical upcycling process recovers over 92 per cent of critical metals from used nickel-lean cathodes, commonly found in spent batteries. Unlike traditional recycling, which is energy-intensive and yields lower-value materials, this method produces high-performance cathode powders. Batteries made from recycled materials retained 88 per cent of their capacity after 500 cycles and over 85 per cent after 900. The new technique uses 8.6 per cent less energy and cuts carbon emissions by nearly 14 per cent. The study highlights a breakthrough that could reduce reliance on mining while tackling battery waste.