Recycling lithium-ion batteries represents one of the greatest challenges and opportunities in moving toward a circular economy and a low-emissions society. Toshiba, in its firm commitment to sustainability and innovation, has taken a step forward with the development of a revolutionary direct recycling method for lithium batteries with oxide anodesThis breakthrough, which positions the Japanese multinational as a leader in the energy transition, not only addresses growing regulatory demands but also paves the way for more efficient use of resources and a drastic reduction in the environmental impact associated with the battery life cycle.
The importance of this innovation is even more relevant in a global context of accelerated electrification, where electric vehicles, consumer electronics, and energy storage systems require new solutions to manage the growing volume of used batteries. The process developed by Toshiba marks a turning point in the sector, offering a more economical, efficient, and sustainable alternative to conventional recycling methods.
Regulatory context and environmental requirements: the framework that drives innovation
La international regulation on batteries, especially that promoted by the European Union, currently requires manufacturers to report the carbon footprint of their products and ensure high levels of sustainability throughout the entire life cycle, including manufacturing, use, and recycling. Recent legislation has resulted in the obligation to declare the carbon footprint (CFP) and adopt processes that minimize environmental impact. This pressure has accelerated the need for new and scalable solutions for battery waste management.
The recycling method developed by Toshiba is based on the direct reuse of the active materials present in the oxide anodes of lithium-ion batteries.This technique takes advantage of a fundamental characteristic of advanced oxides: its stable and resistant crystalline structure. Thanks to this, it is possible to separate the active material from the current collecting sheet of the negative electrode by means of a simple heat treatment, without alterations in the chemical composition or the need for complex reactivation processes.
Traditionally, recycling methods involve the decomposition of active materials into their chemical elements and subsequent resynthesis, which requires large amounts of energy, the use of chemical reagents, and a significant generation of secondary waste. In contrast, Toshiba direct recycling:
- Allows reuse active materials in their original form, keeping the crystalline structure and electrochemical properties intact.
- Drastically reduces energy consumption and the use of hazardous chemicals.
- It reduces the costs associated with the process, both in economic and environmental terms.
- It is applicable to both conventional oxide anodes as well as advanced technologies developed by Toshiba itself, such as niobium-titanium (NTO) anodes.
The key difference with conventional processes is that, thanks to the structural strength of the oxide materialsThe separation of the active material is achieved by simply removing the binder that holds it to the collector film during a controlled thermal process. This prevents deterioration or degradation of the electrochemical properties, optimizing the recyclability and longevity of the components.
Environmental impact: carbon footprint reduction and circular economy
The environmental benefits of this innovation are not limited solely to the reduction in energy and chemical consumption. Toshiba has estimated that its direct recycling process can reduce its carbon footprint by up to 85% compared to using virgin materials that have never been used before.This figure represents an unprecedented advance and consolidates the role of direct recycling as strategic element in the circular economy batteries.
Recycling batteries using this method has very positive consequences:
- Reduces the need for mining extraction of raw materials such as lithium, cobalt, nickel or graphite, mitigating the associated ecological damage.
- Minimizes the generation of hazardous waste and the discharge of polluting substances into the environment.
- It allows you to effectively leverage components that have already proven their performance, extending their useful life in other devices.
This strategy is in line with the global objectives of achieving a carbon-neutral society and progressively reduce dependence on hydrocarbons, while responding to the growing demand for electrification in multiple industrial sectors.
Detailed process operation: efficiency, simplicity and scalability
El direct recycling process Developed by Toshiba, the process involves harnessing the structural stability of the anode's active materials, coated with a thin, current-collecting metal foil. The process, explained in a simple yet technical manner, involves the following steps:
- Reception and preparation: Used batteries or scrap materials from the manufacturing process are collected and prepared for recycling.
- Heat treatment: Controlled heat is applied to break down the binder that fixes the active material to the collector sheet, without affecting the internal structure of the oxide.
- Physical separation: The active material is released from the collector film, resulting in a product that maintains its original electrochemical capabilities.
- Purification step: If necessary, surface impurities are removed to ensure the quality of the recovered material.
- Reuse: Recycled materials are used directly in the manufacture of new electrodes or batteries, thus efficiently closing the life cycle.
Compared to traditional methods (such as conventional recycling of cobalt or nickel cathodes, or the expensive graphite recycling process), Toshiba's direct method simplifies every phase and introduces advantages such as reduced temperatures and the elimination of chemical resynthesis steps. As a result, the risks of structural component degradation are reduced, and a high level of performance is maintained in recycled products.
Performance and durability: comparison with new batteries
One of the key questions surrounding battery recycling concerns the loss of capacity or longevity of reused materials. Extensive testing by Toshiba has shown that batteries made with electrodes recycled using this method retain more than 97% of their original capacity. of new components, after multiple charge and discharge cycles. Furthermore, the lifespan of these recycled batteries is comparable to that of batteries made from virgin materials, validating the process's effectiveness and its potential for widespread market integration.
This success is further extended in the application to advanced anode technologies, such as niobium-titanium oxide (NTO) batteries, which are characteristic of the latest generation of Toshiba batteries. The process not only serves to recycle conventional models, but also enables the circular economy in high-performance products, suitable for commercial electric mobility and stationary storage systems.
Comparison of cathode and anode recycling: challenges and opportunities
In the field of battery recycling, the treatment of cathode materials (with cobalt and nickel) has made significant progress in response to growing regulatory pressure and industrial demand. However, graphite recycling –the most common material in traditional anodes– still poses major difficulties due to structural degradation after use and the costly processes required for its recovery.
The oxide anodes developed by Toshiba (especially those of niobium and titanium), have decisive advantages:
- Greater ease of direct recycling due to its stability and resistance to charge/discharge cycles.
- Less structural degradation compared to graphite, allowing for more reuse.
- superior performance in power and lifespan, suitable for vehicles, industrial applications and advanced mobility.
This approach places Toshiba at the forefront of developing materials that are easier to recycle, offer greater added value, and are clearly focused on future needs in electrification and energy storage.
Industrial and consumer applications: opportunities for scalable recycling
Toshiba's advancement in direct recycling introduces new possibilities in various sectors:
- Electric automotive: It allows recycled materials to be reincorporated into the production of batteries for electric and hybrid cars, contributing to overall cost reduction and compliance with the strictest environmental standards.
- Stationary energy storage: It facilitates the reuse of components in industrial and domestic storage systems, where durability and efficiency are key.
- Consumer electronics: It promotes the integration of recycled materials into smartphones, laptops, and mobility devices, reinforcing the brands' environmental commitment.
- Commercial mobility and clean innovations: It promotes pioneering projects, such as battery-swapping systems or the electrification of commercial fleets and public transport, also benefiting the development of clean aircraft and strategic collaborations (such as the recent one with Airbus for the development of hydrogen aircraft).
Future development and perspectives: towards a real circular economy
Toshiba foresees expand and strengthen its direct recycling system not only through waste management in the manufacturing process, but also by collecting used batteries from the market. The company plans to establish a robust framework for the incorporation of recycled materials in its products, as well as developing new strategies for the recovery and recycling of NTO (niobium-titanium) cells in commercial vehicles and advanced industrial applications.
At the same time, collaboration with international organizations and the promotion of sectoral studies in key regions such as Japan and Europe reinforce the global trend toward more sustainable, reliable, and continuously reused supply chains. Direct battery recycling is thus positioned as the cornerstone of closed-loop product design and the achievement of emission reduction, resource optimization, and regulatory compliance goals.
The innovative lithium battery recycling process developed by Toshiba redefines the standard of sustainability and efficiency in the sector. It is not just a technical solution, but a strategic commitment to a circular, cleaner, and more responsible industry. By simplifying procedures and significantly reducing the environmental footprint, this breakthrough places Toshiba at the forefront of the global energy revolution, paving the way for other manufacturers to follow and making a decisive contribution to environmental protection and sustainable development.
