Aqua Metals, based in Reno, Nevada, has announced the successful completion of bench-scale testing and engineering analysis for its innovative process to recycle lithium iron phosphate (LFP) battery materials. This milestone positions the company as a leader in addressing the recycling challenges posed by LFP batteries, which are becoming the dominant chemistry for electric vehicles (EVs) and stationary energy storage due to their lower cost and safety advantages. The breakthrough highlights Aqua Metals’ commitment to building a sustainable battery supply chain in the U.S.
LFP batteries present unique recycling challenges because their iron-based cathodes lack nickel or cobalt, reducing their market value. Aqua Metals is stepping ahead of domestic recyclers who primarily focus on higher-value chemistries by developing a scalable method to recover lithium from LFP black mass. The company’s engineering analysis indicates that the LFP recycling process can be integrated into its planned Sierra Arc facility with an incremental capital expense of 25–30%, without requiring expansion of the facility’s physical footprint. This integration could potentially double the facility’s total feedstock throughput to 15,000 tons annually and increase lithium carbonate production to approximately 2,700 tons per year.
Upon commissioning, Aqua Metals’ commercial-scale operation would increase total U.S. lithium production by over 50% annually, making it one of the largest domestic producers of battery-grade lithium carbonate. Steve Cotton, Aqua Metals’ President and CEO, emphasized the importance of this milestone: “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.”
Recycling LFP batteries has posed technical hurdles due to their unique chemistry and lower market value. However, Aqua Metals’ platform demonstrates adaptability and scalability, positioning the company as a pioneer in clean and efficient battery recycling solutions for North America’s evolving battery landscape.
