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Two-step flash Joule heating method recovers lithium‑ion battery materials quickly and cleanly

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Two-step flash Joule heating method recovers lithium‑ion battery materials quickly and cleanly


The residue after FJH-Cl2. Credit: Advanced Materials (2025). DOI: 10.1002/adma.202517293

A research team at Rice University led by James Tour has developed a two-step flash Joule heating-chlorination and oxidation (FJH-ClO) process that rapidly separates lithium and transition metals from spent lithium-ion batteries. The method provides an acid-free, energy-saving alternative to conventional recycling techniques, a breakthrough that aligns with the surging global demand for batteries used in electric vehicles and portable electronics.

Published in Advanced Materials, this research could transform the recovery of critical battery materials. Traditional recycling methods are often energy intensive, generate wastewater and frequently require harsh chemicals. In contrast, the FJH-ClO process achieves high yields and purity of lithium, cobalt and graphite while reducing energy consumption, chemical usage and costs.

“We designed the FJH-ClO process to challenge the notion that battery recycling must rely on acid leaching,” said Tour, the T.T. and W.F. Chao Professor of Chemistry and professor of materials science and nanoengineering. “FJH-ClO is a fast, precise way to extract valuable materials without damaging them or harming the environment.”

Quick, controlled heating

The rapid increase in the use of in and consumer electronics has intensified the need for sustainable recycling technologies. Existing recycling methods are often costly and inefficient while producing significant amounts of wastewater.

To tackle these challenges, the research team developed a two-step process that uses brief bursts of heat and air instead of harsh chemicals. First, the battery materials are briefly heated with chlorine gas, which breaks them down. They then undergo a second heating in air, transforming most of the metals into forms that can be separated from lithium. Because lithium does not form an oxide as easily as other metals, it remains as the chloride, which can be easily extracted using water.

Previous methods required lengthy processes and strong acids. The FJH-ClO approach, however, uses fast, controlled heating and simple reactions to make the separation process cleaner and faster.

Holistic recovery

Tests have shown that the new process can recover nearly all valuable materials from used batteries, including lithium, cobalt and graphite, with high purity. Early analyses suggest that even at a small scale, it may require about half as much energy, 95% fewer chemicals and significantly lower costs compared to existing methods.

These results establish a scalable, acid-free approach for the comprehensive recovery of lithium-ion battery materials, offering both environmental and economic advantages while setting a new standard for sustainable battery recycling.

“It’s rewarding to see a process that’s both scientifically sound and practically useful,” said Shichen Xu, the study’s first author and a Rice postdoctoral researcher. “That balance is what makes real-world impact possible.”

Future implications

This process paves the way for large-scale implementation and integration into the battery supply chain. It provides a foundation for recovering valuable materials while reducing the need for virgin mining.

With the FJH-ClO process already proven at the laboratory scale, the researchers plan to scale the process through their startup, Flash Metals U.S., a division of Metallium Ltd.

“This is more than just a lab experiment,” Tour said. “It’s a blueprint for how the industry can meet the demand for battery materials without further straining the planet.”

Co-authors of this study include Justin Sharp, Qiming Liu, Jaeho Shin, Haoxin Ye, Kaiwen Yang, Carter Kittrell, Haojie Zhu, Carolyn Teng, Bowen Li, Shihui Chen and Karla Silva from Rice’s Department of Chemistry; Ralph Abdel Nour from its Applied Physics Program and Smalley-Curl Institute; and Khalil JeBailey, Boris Yakobson and Yufeng Zhao from its Department of Materials Science and NanoEngineering.

More information:
Shichen Xu et al, Holistic Recovery of Spent Lithium‐Ion Batteries by Flash Joule Heating, Advanced Materials (2025). DOI: 10.1002/adma.202517293

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Rice University


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Looking for the Best Smart Scale? Step on Up

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Looking for the Best Smart Scale? Step on Up


Other Smart Scales

Renpho MorphoScan

Photograph: Chris Null

Renpho MorphoScan for $150: The Renpho MorphoScan full-body scanner looks surprisingly similar to the Runstar FG2015, including a near-identical display attached to the handlebars. Well, spoiler alert, they are basically the same scale. They even use the same app to collect data (and you can even use both scales simultaneously with it). The only reason this scale isn’t our top pick for the category is that it’s $15 more expensive. You can rest assured that a price war is looming.

Black digital scale with small screen

Arboleaf Body Fat Scale CS20W

Photograph: Chris Null

Arboleaf Body Fat Scale CS20W for $40: This affordable Bluetooth scale isn’t the most eye-catching I’ve tested, owing to its big, silver electrodes and an oversized display that comes across as a bit garish. While weight is easy to make out, the six additional statistics showcased are difficult to read, all displayed simultaneously. I like the Arboleaf app better than the scale, where five more metrics can be found in addition to the seven above, each featuring a helpful explanation when tapping on it. It’s a solid deal at this price, but the upsell to get an “intelligent interpretation report” for an extra $40 per year is probably safe to skip.

Image may contain Electronics Phone Mobile Phone Computer Laptop and Pc

Hume Health Body Pod

Photograph: Chris Null

Hume Health Body Pod for $183: Hume Health’s Body Pod, another full-body scanner with handles, is heavily advertised—at least to the apps on my phone—and touted (by Hume) as the Next Big Thing in the world of body management. While the app is indeed glossy and inviting, I was shocked to discover how flimsy the hardware felt, that it lacked Wi-Fi, and that some features are locked behind a $100-a-year Hume Plus subscription plan. It works fine enough, but you can get results that are just as good with a cheaper device.

Garmin Index S2 for $191: Five years after its release, the Index S2 is still Garmin’s current model, a surprise for a company otherwise obsessed with fitness. It’s still noteworthy for its lovely color display, which walks you through its six body metrics (for up to 16 users) with each weigh-in. The display also provides your weight trend over time in graphical form and can even display the weather. The scale connects directly to Wi-Fi and Garmin’s cloud-based storage system, so you don’t need a phone nearby to track your progress, as with Bluetooth-only scales. A phone running the Garmin Connect app (Android, iOS) is handy, so you can keep track of everything over time. Unfortunately, as health apps go, Connect is a bit of a bear, so expect a learning curve—especially if you want to make changes to the way the scale works. You can turn its various LCD-screen widgets on or off in the app, but finding everything can be difficult due to the daunting scope of the Garmin ecosystem. The color screen is nice at first, but ultimately adds little to the package.

Omron BCM-500 for $92: With its large LCD panel, quartet of onboard buttons, and oversize silver electrodes, the Omron BCM-500 is an eye-catching masterwork of brutalist design. If your bathroom is decked out in concrete and wrought iron, this scale will fit right in. The Bluetooth unit syncs with Omron’s HeartAdvisor app (Android, iOS), but it provides all six of its body metrics directly on the scale, cycling through them with each weigh-in (for up to four users). It can be difficult to read the label for each of the data points, in part because the LCD isn’t backlit, but the app is somewhat easier to follow, offering front-page graphs of weight, skeletal muscle, and body fat. On the other hand, the presentation is rather clinical, and the app is surprisingly slow to sync. For a scale without a Wi-Fi connection, it’s rather expensive too.


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To Start Doing What You Want to Do, First Do Less

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To Start Doing What You Want to Do, First Do Less


This applies not just to things you have to do, but also things you think you want to do. Maybe you think you should learn Spanish, but you haven’t done anything to actually learn Spanish. Admitting that you aren’t actually committed to the idea enough to do the work of learning Spanish can help close that loop. Letting go of that feeling that you should learn Spanish just might be the thing that frees up your mind enough that you decide to take up paddleboarding on a whim. The point is that the new year isn’t just a time for starting something new. It’s a time to let go of the things from that past that are no longer serving you.

In many ways this is the antidote to that ever-so-popular slogan “Just do it.” Just do it implies that you shouldn’t think about it, instead of deciding what you really want to do or should do. Maybe spend some time remembering why you wanted to do it in the first place, and if those reasons no longer resonate with you, just don’t do it.

If you like this idea, I highly recommend getting Allen’s book. It goes into much more detail on this idea and has some practical advice on letting go. You can still keep track of those things, in case you do decide, years from now, when you’re paddleboarding through the Sea of Cortez, that now you really do want to learn Spanish and are willing to do the work.

Remember to Live

I will confess, my enthusiasm for Getting Things Done has waned over the years. Not because the system doesn’t work, but because I have found my life more dramatically improved by doing less, not more. It’s not that I’ve stopped getting things done. It’s that I’ve found many of the things I felt like I should do were not really my idea; they were ideas I’d internalized from other places. I didn’t really want to do them, so I didn’t, then I felt guilty about it.

While everything I’ve written above remains good advice for starting a healthy habit and keeping it going, it’s worth spending some time and making sure you know why you want to do what you’re doing. I have been rereading Bertrand Russell’s In Praise of Idleness, and this line jumped out at me: “The modern man thinks that everything ought to be done for the sake of something else, and never for its own sake.”



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Oh No! A Free Scale That Tells Me My Stress Levels and Body Fat

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Oh No! A Free Scale That Tells Me My Stress Levels and Body Fat


I will admit to being afraid of scales—the kind that weigh you, not the ones on a snake. And so my first reaction to the idea I’d be getting a free body-scanning scale with a Factor prepared meal kit subscription was something akin to “Oh no!”

It’s always bad or shameful news, I figured, and maybe nothing I don’t already know. Though, as it turned out, I was wrong on both points.

Factor is, of course, the prepared meal brand from meal kit giant HelloFresh, which I’ve tested while reviewing dozens of meal kits this past year. Think delivery TV dinners, but actually fresh and never frozen. Factor meals are meant to be microwaved, but I found when I reviewed Factor last year that the meals actually tasted much better if you air-fry them (ideally using a Ninja Crispi, the best reheating device I know).

Especially, Factor excels at the low-carb and protein-rich diet that has become equally fashionable among people who want to lose weight and people who like to lift it. Hence, this scale. Factor would like you to be able to track your progress in gaining muscle mass, losing fat, or both. And then presumably keep using Factor to make your fitness or wellness goals.

While your first week of Factor comes at a discount right now, regular-price meals will be $14 to $15 a serving, plus $11 shipping per box. That’s less than most restaurant delivery, but certainly more than if you were whipping up these meals yourself.

If you subscribe between now and the end of March, the third Factor meal box will come with a free Withings Body Comp scale, which generally retails north of $200. The Withings doesn’t just weigh you. It scans your proportions of fat and bone and muscle, and indirectly measures stress levels and the elasticity of your blood vessels. It is, in fact, WIRED’s favorite smart scale, something like a fitness watch for your feet.

Anyway, to get the deal, use the code CONWITHINGS on Factor’s website, or follow the promo code link below.

Is It My Body

The scale that comes with the Factor subscription is about as fancy as it gets: a $200 Body Comp scale from high-tech fitness monitoring company Withings. The scale uses bioelectrical impedance analysis and some other proprietary methods in order to measure not just your weight but your body fat percentage, your lean muscle mass, your visceral fat, and your bone and water mass, your pulse rate, and even the stiffness of your arteries.

To get all this information, all you really need to do is stand on the scale for a few minutes. The scale will recognize you based on your weight (you’ll need to be accurate in describing yourself when you set up your profile for this to work), and then cycle through a series of measurements before giving you a cheery weather report for the day.

Withings

Body Comp Smart Scale

Your electrodermal activity—the “skin response via sweat gland stimulation in your feet”—provides a gauge of stress, or at least excitation. The Withings also purports to measure your arterial age, or stiffness, via the velocity of your blood with each heartbeat. This sounds esoteric, but it has some scientific backing.

Note that many physicians caution against taking indirect measurements of body composition as gospel. Other physicians counter that previous “gold standard” measurements aren’t perfectly accurate, either. It’s a big ol’ debate. For myself, I tend to take smart-scale measurements as a convenient way to track progress, and also a good home indicator for when there’s a problem that may require attention from a physician.

And so of course, I was petrified. So much bad news to get all at once! I figured.



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