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Green Li-ion launches N America’s first commercial-scale plant to produce recycled Li-ion engineered battery materials

Green Li-ion, a lithium-ion battery recycling technology company, launched its first commercial-scale installation to produce sustainable, battery-grade materials—the first of its kind in North America.

The plant, located within an existing recycling facility, will produce battery-grade cathode and anode materials from concentrated components of spent batteries using Green Li-ion’s patented multi-cathode-producing Green-hydrorejuvenation technology.


Battery-grade precursor cathode active material (pCAM) produced by the recycling unit in Atoka, Oklahoma.

The current recycling process for spent lithium-ion batteries in North America includes sorting batteries before shredding, which are then processed into “black mass” and further into sulfates. The material is then exported overseas, most often to China and South Korea, for further processing.

Green Li-ion’s patented technology utilizes a novel hydrometallurgical approach that closes the recycling loop by directly converting recycling scrap into battery-grade precursor cathode active material (pCAM) without being exported for further processing.

In contrast to legacy processes, Green Li-ion’s process significantly reduces production time, yielding pCAM in around 12 hours. It also offers environmental benefits, emitting up to 90% fewer GHG emissions than virgin materials processing.

The Green Li-ion installation is the first plant on the continent capable of processing unsorted black mass of different Li-ion battery chemistries into pCAM at commercial scale, ensuring 99% purity. The Atoka plant and all other Green Li-ion installations are fully customizable, capable of producing materials meeting the specifications battery cell producers require, and based on customers’ desired material output from the plant.

Green Li-ion offers flexible options for manufacturers and recyclers to utilize its technology either through a licensing agreement that allows the plant to be installed in their own facilities or through a tolling agreement where they can send their black mass to Green Li-ion-owned plants for processing directly into battery materials.

This flexibility allows customers to integrate Green Li-ion’s technology seamlessly into their production process, allowing for greater control over critical mineral supply. Alternatively, customers can adjust their supply chains and associated costs via tolling. In addition, the modular nature of Green Li-ion systems allows for rapid deployment and setup that enables operations to begin in a few months instead of building dedicated infrastructure over several years.

By on-shoring black mass and battery waste processing with cathode and anode material production, battery manufacturers and recyclers can significantly reduce the cost and CO2 emissions impacts of their operations and supply chains. Provisions in the Inflation Reduction Act (IRA) have made domestic battery recycling even more attractive, due to tax credits for companies that manufacture batteries in the US and credits for companies using recycled battery materials.

The Green Li-ion plant in Atoka is expected to create two metric tons of pCAM at battery grade, or the equivalent of 72,000 smartphone batteries per day, with plans to quadruple this capacity within the coming year.

Green Li-ion has developed technology to process lithium iron phosphate (LFP) batteries to extract battery-grade iron phosphate plus lithium and graphite. Currently, there are a limited number of lab/pilot-stage LFP battery recycling projects.


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