Battery Waste to Valuable Methane

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Methane is the main constituent of the natural gas we may use for cooking, heating, and powering vehicles. We note that this is a greenhouse gas, but at least it is a step away from coal and oil. Researchers at Technical University of Vienna have found a way to convert used nickel-metal-hydride battery waste to valuable methane, but only after recovering the nickel first.

Producing Nickel and Methane from Battery Waste

The Technical University of Vienna overview, that we link to below, is quite complex, and so we begin with a brief introduction:

  • Recycling and recovering nickel-metal-hydride battery materials is technologically challenging.
  • Recovering nickel from used batteries and production scrap, could meet 18% of European requirements.
  • Current UK and European recycling capacity is only around 10% of projected 2030 targets.
  • The researchers used a two-step process, which allowed them to convert battery waste to valuable methane.

First, they extracted the nickel from used nickel-metal-hydride batteries, and set it to one side. Then they laid their hands on a supply of used aluminum foil, and produced aluminum oxide from it.

Aluminum oxide is a compound of aluminum and oxygen that has relatively high thermal conductivity, and  catalyses a variety of industrial processes. It is also widely used to remove water from gas streams.

Finally, the Vienna team converted some of the recovered nicked and aluminum oxide into a powerful nanocatalyst, in an environmentally friendly way.

“Our nanocatalyst consists of 92-96% aluminum oxide, and 4-8% nickel,” explains Prof Rupprechter. “This is ideal for converting the greenhouse gas carbon dioxide, together with hydrogen, into methane.

“Our process for converting nickel-metal-hydride battery waste to valuable methane requires neither high pressure, nor high temperatures,” he continues. “The catalyst works at normal atmospheric pressure,  and an easily achievable temperature of 250°C / 482°F .”

“Used catalysts can be broken down back into their original components, so that they can be reused, closing the sustainability loop,” adds Dr. Qaisar Maqbool. “This ensures that the entire process remains environmentally friendly, and that the amount of waste is minimized.”

More Information

Green Nickel for Sustainable Electrification

Why We Owe Our Life to CO2 and Methane

Preview Image: Characterization Of Prepared Nanocatalyst 

Technical University of Vienna Overview 10 March 2025

Research Findings in Green Chemistry Issue 10, 2025

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About Author

Electricity has always intrigued me. I have been writing about batteries and energy storage for more than ten years, and have published over 4,000 articles on this website. During that time, I have researched developments across lead-acid, lithium-ion, sodium-ion, flow batteries, and emerging energy-storage technologies. My goal is to explain complex battery concepts in clear, practical language that anyone can understand. My writing career began unexpectedly after leaving the corporate world. What started as a search for a new direction gradually became a fascination with batteries, renewable energy, and the science that powers modern life. Writing may not have made me wealthy, but it has given me the opportunity to explore an industry that continues to evolve in remarkable ways.

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