Restores 95% Performance to Waste Batteries Without Shredding… Cornell University Unveils 'Electrode Regeneration' Process
Date
Jun 28, 2026
Classification
- Trends/Industries
Researchers at Cornell University have developed a process to restore end-of-life lithium-ion batteries to 95% of their original performance by immersing them in an electrochemical solution without crushing them. This technology is estimated to reduce cell manufacturing costs by 56% compared to existing recycling methods. The research results were published in the international journal *Energy and Environmental Sciences (EES)*.
Researchers at Cornell University in the United States have developed an electrochemical process that restores spent lithium-ion batteries to about 95% of their original capacity by regenerating the electrodes without crushing them, the science media outlet New Atlas reported on the 25th (local time).
'DEER' Process Emerges to Revitalize Electrodes by Melting Only the Thickened SEI Layer
In lithium-ion batteries, repeated charging and discharging causes the 'Solid Electrolyte Interface (SEI)' layer to gradually thicken on the electrode surface, increasing resistance and reducing capacity. The research team focused on the fact that this thickened SEI layer merely covers the electrode surface without damaging the electrode's basic structure itself. Accordingly, they proposed a 'Direct Electrode Regeneration (DEER)' process in which the electrodes are completely separated from the spent battery without crushing, and then immersed in a '1,3-dimethyl-2-imidazolidinone' solution while still connected to a metal current collector. The solution selectively dissolves only the SEI layer that was impairing performance, restoring the electrode to a near-new condition.
56% reduction in cell manufacturing costs… also reduced usage of hazardous substances and water
The research team analyzed economic feasibility and environmental impact using open-source software developed by the Rissel Center at Argonne National Laboratory. The results showed that the DEER process reduces cell manufacturing costs by 56% compared to existing battery recycling methods. By eliminating conventional dry and wet smelting extraction processes, costs, time, and energy are saved, and emissions of hazardous air pollutants and water usage are also reduced. During the regeneration process, a thin layer of lithium fluoride (LiF) forms on the electrode surface, acting as a protective barrier to suppress the excessive growth of SEI; consequently, batteries made from the regenerated electrodes demonstrated high cycle stability.
The next task is to resolve other causes of degradation, such as 'lithium loss'.
Viva Carla, a professor of chemical engineering at Cornell University and the lead researcher, explained that this method involves repairing and reusing batteries as they are without crushing them. She noted that the dissolution process is key to capacity recovery, with a recovery rate of approximately 95%. The research team stated that the waste batteries currently being processed maintain 70–80% of their initial performance, which is typical for batteries discarded from electric vehicles. In the future, they aim to further extend battery life by addressing other forms of degradation mechanisms, such as lithium loss.
Unlike conventional recycling methods that crush entire electrodes to extract core minerals, Cornell University's DEER process removes only the SEI layer while preserving the electrodes, thereby simultaneously reducing costs and environmental burdens. With the volume of waste batteries from electric vehicles and ESS projected to reach 100 trillion won by 2040, attention is focused on whether this new approach of 'electrode regeneration'—rather than mineral extraction—will expand the options for the battery circular economy.
#WasteBattery #BatteryRecycling #Cornell #DEERProcess #LithiumIonBattery
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