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Recovering critical materials from used electronics

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Technologies developed at Oak Ridge National Laboratory to efficiently recover valuable electronic components are being commercialized by Appalachian Renewal Technologies. Credit: Carlos Jones/ORNL

Technologies developed at Oak Ridge National Laboratory to efficiently recover valuable electronic components are being commercialized by Appalachian Renewal Technologies. 

Why it matters:  

Discarded electronics are multiplying as Americans upgrade old computers, cell phones, and vehicles. Recovering valuable materials from these waste streams reduces the need for new sources of rare earth minerals used in magnets that store data in hard drives, alleviates supply chain bottlenecks, and reduces American dependence on foreign sources for critical materials. 

The innovation:  

  • An automated system for extracting rare earth materials from used hard drives
  • A process for recovering cathode materials from spent lithium-ion batteries, using a less toxic solvent than the industry standard
  • A method for direct recovering lithium-ion anode battery scraps from initial manufacturing for use in new electrodes 

Real-world impact: 

A partner company based in Appalachia plans to create high-value product streams at a regional facility incorporating the ORNL-developed technologies, bringing skilled jobs and economic growth opportunities to the region. 

The benefits:  

  • Scarce graphite and rare cobalt can be captured from spent batteries and reused in new ones.
  • Battery innovations tackle one of the most difficult steps in battery de-manufacturing: separating the thin metal electrode layers from the metal film that serves as a current collector.
  • The electrode recovery methods utilize lower-cost inputs, such as water or chemicals that can be reused, reducing the size of the facility footprint and cost of disposal.
  • Magnets extracted using ORNL’s hard-drive disassembly conveyor processing system can be used directly for manufacturing new hard drives or motor assemblies, reshaped or resized for other applications, or processed back to rare earth metal.
  • The automated disassembly process separates other commodity materials that have a viable resale market, such as aluminum, steel, nickel, and printed circuit boards.
  • The approach can be adapted to target other consumer goods containing rare earth magnets, such as used electric motors, appliances, and heating and air conditioning systems. 

Backed by science:  

This electrode recovery research was supported by the Department of Energy’s Vehicle Technologies Office. Development of the hard drive disassembly system was supported by DOE’s Advanced Materials and Manufacturing Technologies Office through the Critical Materials Innovation Hub. 

Deep dive:  

The big picture:  

These innovations fill a gap in the supply chain, address a growing waste disposal problem, and open the door to developing a new branch of the U.S. electronics industry. 

Read more stories about ORNL's science with impact.