Aqua Metals Produces First-Ever Cathode Active Material from 100% Recycled Nickel
Lithium-ion battery recycler Aqua Metals has successfully produced what it claims to be the first cathode active material (CAM) made entirely from domestically sourced recycled nickel. This breakthrough represents a significant step toward building a cleaner and more secure U.S. battery supply chain.
Using its proprietary AquaRefining process, Reno-based Aqua Metals recovered high-purity nickel from spent lithium-ion batteries and battery manufacturing scrap. The recycled nickel was refined into battery-grade nickel nitrate, a key precursor in advanced cathode production. A domestic CAM manufacturing partner then used a low-carbon process to convert the nickel nitrate into battery-grade CAM, which is now undergoing validation testing by a Tier 1 lithium battery manufacturer.
Initial tests indicate that the recycled nickel CAM meets industry-standard chemical and electrochemical specifications, ensuring compatibility with existing cell production processes. Further qualification testing is ongoing to assess long-term performance metrics.
The closed-loop production process employed by Aqua Metals and its partner reduces the carbon footprint of CAM manufacturing by an estimated 87% compared to sourcing from China. The company highlights that its AquaRefining process eliminates waste and emissions typically associated with conventional metal refining methods such as smelting and hydrometallurgy. The CAM manufacturing partner also employs a low-carbon, scrap-reducing process that avoids sodium sulfate production, a major environmental burden of traditional CAM manufacturing.
Aqua Metals President and CEO Steve Cotton emphasized the significance of this achievement, stating, "This milestone confirms that Aqua Metals’ technology enables the reclamation and reuse of critical minerals entirely within the United States, supporting both energy security and the clean energy economy."
The company sees this breakthrough as a scalable model for the future of sustainable battery material production, paving the way for further expansion of U.S.-based battery recycling and material supply chains.
