Prototype lithium ion batteries match virgin material performance in Japan

A consortium of six Japanese companies has successfully verified the performance of prototype lithium-ion batteries manufactured using recycled cathode materials. Conducted under the Re-CIRCLE Project, the demonstration confirmed that battery cells created from recovered rare metals match the operational standards of cells made with virgin resources.

The participating entities comprise MARKTEC Corporation, KDDI Corporation, Re-Teck Renewable Energy Solutions Co., Ltd., Emulsion Flow Technologies Ltd., MOL Logistics Co., Ltd., and transcosmos inc. The project team recovered spent lithium-ion battery cells and processed them into high-purity black mass at a facility operated with low environmental impact. Emulsion Flow Technologies Inc. then applied its proprietary solvent extraction technology to recover high-purity rare metals, including lithium, cobalt, and nickel, which were subsequently re-synthesised into cathode materials for prototype production.

Comprehensive testing evaluated the prototype batteries across key physical and electrical metrics. The recycled cells demonstrated electrode volume resistivity, interfacial resistance, rate characteristics across discharge currents from 0.1C to 2C, and cycle durability equivalent to control batteries manufactured using standard commercial lithium carbonate. The test proved that recycled resources satisfy strict performance criteria without sacrificing power output or lifespan.

With technical validation, it promises a closed-loop horizontal recycling system for commercial resource circulation. The Re-CIRCLE Project incorporates collection mechanisms, performance testing, specialised transport, and digital traceability systems. As global industrial demand for energy storage accelerates, establishing secure, domestic supply chains for critical metals provides an essential alternative to primary extraction.