**Executive Summary**
Researchers at the International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI) have developed a technology to repurpose spent graphite from end-of-life lithium-ion batteries into high-value catalysts for fuel cells. The study, published in March 2026, demonstrates that chemically exfoliated graphite improves the efficiency, durability, and methanol tolerance of platinum-based catalysts in acidic media. This innovation addresses the critical challenges of battery waste management and the high cost of fuel cell commercialization.
**Key Points / Main Content**
**Technological Development**
* Graphite is recovered from spent lithium-ion batteries and chemically exfoliated to increase surface area and edge functional groups.
* The material is integrated with platinum-based catalysts to facilitate the oxygen reduction reaction (ORR).
* The research specifically demonstrates performance in acidic media, a departure from earlier studies focused on alkaline media or direct battery reuse.
**Technical Performance and Optimization**
* Exfoliated graphite forms a conductive network that enhances electronic conductivity and oxygen transport.
* The material acts as a chemical barrier that suppresses methanol oxidation and protects platinum from carbon monoxide (CO) poisoning.
* Scientists identified an optimum composition of 10 wt% exfoliated graphite for maximum performance and long-term stability.
**Sustainability and Industry Goals**
* The process converts battery waste into a high-value functional material, promoting sustainable recycling practices.
* The technology reduces reliance on expensive catalyst materials, potentially lowering the cost of fuel cells.
* The innovation supports clean energy advancement, improved energy security, and reduced environmental impact.
**Impact Analysis**
**Research Institutions (ARCI/DST)**
**Impact**
Successfully developed and characterized a novel method for repurposing waste into high-performance electrocatalysts, advancing the field of sustainable resource management.
**Action Required**
Continue optimization and physicochemical characterization to facilitate the transition from laboratory research to industrial application.
**Lithium-ion Battery Recycling Industry**
**Impact**
The discovery provides a high-value application for recovered graphite, which was previously considered waste or low-value material.
**Action Required**
Adopt recovery techniques that allow for the efficient extraction and chemical exfoliation of graphite from end-of-life batteries.
**Fuel Cell Manufacturers**
**Impact**
Access to a more durable and cost-effective catalyst material that improves the performance of Direct Methanol Fuel Cells.
**Action Required**
Explore the integration of the identified 10 wt% exfoliated graphite-platinum composition into fuel cell hardware to enhance commercial viability.
**Environmental and Energy Policy Makers**
**Impact**
The technology contributes to national goals regarding waste reduction, clean energy technology, and improved energy security.
**Action Required**
Promote and support the commercialization of sustainable battery recycling and fuel cell technologies.
Key Entities Referenced
Department of Science and Technology (DST): The central government department that oversees and supports the research activities of ARCI.
International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI): An autonomous institute of the Department of Science and Technology that developed the technology to repurpose spent graphite from lithium-ion batteries for fuel cell catalysts.
Ministry of Science & Technology
Scientists harness the second life of a spent
battery material
Posted On: 30 MAR 2026 3:37PM by PIB Delhi
A new technology for the reuse of spent graphite recovered from end-of-life lithium-ion batteries could
convert battery waste into a high-value functional material that improves fuel cell efficiency.
With the rapid growth of lithium-ion batteries and fuel cell technologies, managing battery waste and the
need for cost-effective, durable fuel cell catalysts are critical challenges.
Scientists have been exploring whether recycled battery materials could be repurposed to address key
performance limitations in fuel cells, and they have zeroed in on graphite, a functional additive in
platinum-based oxygen reduction reaction (ORR) electrocatalysts.
Researchers from International Advanced Research Centre for Powder Metallurgy and New Materials
(ARCI), an autonomous institute of the Department of Science and Technology (DST), recovered graphite
from spent lithium-ion batteries and chemically exfoliated it to increase surface area and the number of
edge functional groups. They also carried out extensive physicochemical characterization, electrochemical
evaluation for ORR and methanol tolerance, optimization of composition for maximum performance and
stability. The research published in the journal ACS Sustainable Resource Management.
Fig: Graphical illustration of the Pt–exfoliated graphite catalyst, with exfoliated graphite forming a
conductive network that suppresses methanol crossover and CO poisoning, leading to improved oxygen
reduction performance and durability
Unlike earlier studies focused solely on alkaline media or on battery reuse, this work demonstrates
methanol-tolerant ORR in acidic media using recycled graphite.When integrated with platinum catalysts, the exfoliated graphite formed a conductive network that
enhanced both electronic conductivity and oxygen transport while selectively adsorbing methanol
molecules. This also acted as a chemical barrier that suppressed methanol oxidation and platinum CO
poisoning. An optimum composition of 10 wt % exfoliated graphite was identified, offering superior
performance and durability.
This prevents methanol oxidation and CO poisoning of platinum under acidic conditions relevant to Direct
Methanol Fuel Cell operation, thereby improving ORR performance and long-term stability. As a result,
methanol tolerance improves and electrocatalytic performance enhances while protecting platinum from
carbon monoxide (CO) poisoning.
This would help promote sustainable recycling of lithium-ion batteries, reduces reliance on costly catalyst
materials, enhances clean energy technologies, supports fuel cell commercialization, and contributes to
reduced environmental impact and improved energy security.
*****
NKR/FT
(Release ID: 2246858) Visitor Counter : 170
Read this release in: Urdu , ही , Marathi