Toray unveils scalable nanofiltration technology enabling over 95% lithium recovery from used batteries, supporting efficient recycling and future clean energy transitions.
Toray Industries, Inc. has revealed a significant technological advancement with the development of a scalable, high-durability, and high-selectivity nanofiltration membrane element designed to recover exceptionally high yields of high-purity lithium from used automotive lithium-ion batteries. This innovation represents an important step forward in addressing a major gap in current battery recycling processes, where a substantial portion of valuable lithium is commonly lost or discarded. By enabling more efficient recovery, Toray鈥檚 technology supports the creation of a more sustainable and circular resource cycle for lithium, which is becoming increasingly essential as countries work toward decarbonization and greater adoption of electric vehicles.
As the global shift toward electrified mobility accelerates, establishing a closed-loop system for battery materials鈥攑articularly lithium鈥攊s becoming a crucial industrial and environmental priority. The rapid rise in the use of lithium iron phosphate (LFP) batteries, which do not contain nickel or cobalt, has further increased the urgency of developing sophisticated methods for efficiently reclaiming lithium in large volumes. Toray鈥檚 latest nanofiltration technology directly addresses this need by offering a process that can recover lithium with high purity and yield from a wide range of lithium-ion battery chemistries, including both nickel-cobalt variants and LFP batteries. Beyond lithium, the system also enables recovery of other strategic metals such as nickel and cobalt, which are essential for manufacturing next-generation batteries.
Historically, Toray鈥檚 nanofiltration membranes have been applied to the extraction of lithium from natural salt lake brines. However, recovering lithium from end-of-life batteries introduces an entirely different challenge: the filtration of highly acidic sulfuric acid leachate produced when these batteries are processed into black mass. Conventional membranes lack the acid resistance needed for such harsh conditions, limiting their functionality. To overcome this, Toray engineered an advanced nanofiltration membrane exhibiting superior acid resistance while maintaining high selectivity and long-term durability. Through rigorous laboratory-scale demonstrations, the company has achieved lithium recovery rates exceeding 95%, marking what Toray describes as the world鈥檚 first membrane-based method capable of selectively separating and recovering lithium from battery-derived leachate.
The breakthrough became possible through Toray鈥檚 deep expertise in organic synthesis, polymer chemistry, and nanotechnology. Leveraging these strengths, the company successfully upscaled the technology, enabling the production of full-size membrane elements similar to those used in standard water treatment facilities. This scalability is a crucial milestone, as it allows Toray to begin supplying product samples to industry partners and accelerate the pathway toward commercialization and real-world deployment.
Toray is now working to reinforce its production capabilities in anticipation of domestic and international demand. Notably, demonstration projects funded by Japan鈥檚 Ministry of the Environment in fiscal year 2023 played an important role in validating and refining the technology. These projects were part of broader initiatives aimed at enhancing renewable energy-related products and establishing a nationwide closed-loop recycling structure.
Looking ahead, Toray remains committed to ongoing research and development aimed at advancing innovative materials that contribute to industrial sustainability and broader social progress. The company views this technological achievement as a pivotal step toward more sustainable battery resource management and a cleaner global energy future.
