Scalable ultrafast regeneration of cathodes from battery waste

Lithium cobalt oxide (LiCoO 2 ) accounts for over 70 % of global cobalt consumption, primarily in batteries used in consumer electronics. Its conventional synthesis is energy-intensive and relies on increasingly scarce raw materials. Recycling and regeneration of LiCoO 2 have therefore, become critical. Existing recycling methods often involve high energy consumption, complex processing, and material loss. This work reports a hybrid thermochemical regeneration strategy integrating selective leaching, a glucose-assisted self-sustaining reaction, and brief oxidative annealing to recover high-purity LiCoO 2 from spent batteries. Metal nitrates extracted from spent electrodes react with glucose to form Co, CoO, and Li 2 CO 3 in minutes, followed by complete conversion to phase-pure LiCoO 2 at 850 °C within 10 min. These processes generate localized heat, suppress lithium volatilization, and enable ultrafast regeneration, reducing synthesis time by over 50-fold compared to conventional routes. The regenerated LiCoO 2 exhibits high crystallinity and electrochemical performance comparable to commercial materials at 1C, with ~100 % coulombic efficiency and stable cycling. Technometric analysis shows that the process consumes ~8 MJ/kg of feedstock and emits ~800 g CO 2 /kg, the lowest among existing recycling methods. Furthermore, the process yields more valuable products without the need for resynthesis, with a net economic return of ~$3690 per ton of spent LiCoO 2 batteries. • Glucose-fueled reaction regenerates LiCoO 2 in 10 min at 850 °C. • Cobalt forms via nitrate reduction, then reacts with Li 2 CO 3 to yield LiCoO 2. • Regenerated cathodes match commercial ones in capacity and efficiency. • Scalable regeneration achieved using a standard tube furnace and batch cycling. • Lowest CO 2 output and ~ $3690 profit per ton of recycled battery waste.