Recyclus Group Develops Safe and Scalable LTC Battery Recycling Process

ecyclus Group has reached a significant milestone in battery recycling innovation with the successful completion of an in-depth study in partnership with energy materials researchers at Coventry University. This £100,000 project, funded by Connected Places Catapult, focused on developing a safe and scalable recycling process for lithium thionyl chloride (LTC) cells. The findings represent a crucial advancement in recovering valuable materials while reinforcing the UK’s Critical Minerals Strategy.

LTC cells are widely used in applications where long-lasting, reliable power is required, such as smart water and gas meters, emergency lighting, industrial smoke alarms and offshore energy. With hundreds of tonnes of these batteries reaching end-of-life annually, their safe disposal and material recovery have become a growing concern. The highly reactive metallic lithium and other hazardous chemicals they contain pose unique challenges, making conventional recycling methods both complex and hazardous.

Recognising the need for a specialised approach, Recyclus Group has developed an advanced recycling process that ensures both safety and efficiency. Our key innovations include:

• Controlled discharge technology, enabling the rapid and safe neutralisation of residual charge, reducing the risk of thermal runaway.

• Inert atmosphere shredding, a technique that isolates the battery materials from oxygen to prevent unwanted chemical reactions.

• Advanced filtration and neutralisation systems, effectively capturing and scrubbing hazardous emissions to ensure compliance with stringent environmental regulations.

• Material recovery optimisation, allowing for the extraction of lithium and other valuable components, which can be repurposed for new lithium-ion batteries.

Our collaboration with Coventry University provided critical insights into material behaviour during the recycling process, allowing us to refine our methodologies and enhance recovery efficiency. Through detailed material analysis, we have gained a deeper understanding of how to maximise the extraction of valuable components while mitigating safety risks.

Beyond the technological advancements, this project underscores the increasing economic potential of LTC battery recycling. With an opportunity spanning thousands of tonnes annually and representing a multimillion-pound market, investing in scalable recycling solutions not only addresses environmental concerns but also enhances the UK’s domestic supply of essential materials. As battery technology continues to evolve, ensuring a circular economy for these critical resources will be paramount to achieving long-term sustainability.

At Recyclus Group, we are committed to advancing next-generation recycling solutions that enhance resource recovery, minimise environmental impact and support the UK’s transition towards a more resilient battery ecosystem. By leveraging cutting-edge research and innovative technologies, we continue to lead the way in transforming battery waste into valuable assets, setting new industry benchmarks in safety, efficiency and environmental stewardship.