Aqua Metals Pioneers U.S. Domestic LFP Battery Recycling with Breakthrough Testing

Aqua Metals, a Reno-based company in sustainable lithium-ion battery recycling, has announced a significant achievement: the successful completion of bench-scale testing and engineering analysis for a new process designed to recycle lithium iron phosphate (LFP) battery materials. This achievement positions Aqua Metals as a pioneer in domestic LFP recycling and reaffirms its role as a leader in developing a resilient, circular supply chain for critical battery materials in the United States.

The company said that as the adoption of electric vehicles (EVs) and energy storage systems continues to rise, LFP batteries are quickly becoming the dominant battery chemistry, thanks to their lower cost, enhanced safety, and longer lifespan compared to traditional lithium chemistries. However, Aqua Metals noted that the widespread use of LFP batteries presents a unique recycling challenge. LFP batteries use iron-based cathodes that do not contain nickel or cobalt, making them less economically viable to recycle in comparison to other lithium-ion chemistries. Meanwhile, global lithium prices remain volatile, exacerbating the difficulty of recycling these materials profitably.

While many U.S. recyclers continue to focus on higher-value chemistries, Aqua Metals is taking a proactive approach, the company emphasized. By developing an innovative method for extracting lithium from LFP black mass, Aqua Metals is positioning itself as the first mover in “addressing this underserved and critical segment of the U.S. battery supply chain”.

“We believe this is an important step in our strategy to develop the most adaptable and scalable lithium battery recycling platform in the industry,” said Steve Cotton, President and CEO of Aqua Metals. “Our ability to integrate LFP recovery into our existing plans demonstrates how we can evolve with market needs while maintaining a focus on efficiency, sustainability and long-term impact.”

According to Aqua Metals’ engineering and technoeconomic analysis, the new LFP recycling process can be seamlessly integrated into the planned Sierra ARC facility or any of its ARC facilities. This integration would only require an additional capital expenditure of 25-30% without the need to expand the physical infrastructure of the facility. The Sierra ARC is currently designed to process approximately 7,500 tonnes of NMC-type (nickel-manganese-cobalt) black mass per year, Aqua Metals highlighted. By adding the capability to recycle LFP materials, the facility could process an additional 7,500 tonnes of LFP feedstock annually. This would effectively double the facility’s total throughput and increase lithium carbonate production to around 2,700 tonnes per year.

Once operational, this commercial-scale facility could increase total U.S. lithium production by more than 50% annually, establishing Aqua Metals as one of the largest producers of domestic, battery-grade lithium carbonate. The significance of this cannot be overstated, as the U.S. seeks to become more self-reliant in the production of critical materials for clean energy technologies, including EVs and renewable energy storage systems.

Ben Taecker, Aqua Metals’ Chief Engineering and Operating Officer, emphasized the technical challenges of LFP recycling, noting that its unique chemistry and lower market value have made it a significant hurdle for the industry. “This milestone demonstrates how adaptable our technology platform is, and positions Aqua Metals at the forefront of building the next generation of clean, scalable recycling solutions for the evolving battery landscape in North America.”

With this achievement, Aqua Metals is well-positioned to meet the growing demand for LFP recycling, ensuring that valuable lithium stays within the domestic supply chain. This move aligns with broader U.S. efforts to strengthen energy independence and lead the transition to clean energy, contributing to both the economic and environmental goals of the nation.

Source: Aqua Metals