nth cycle | Metals Processing Revolution for Recycling & Mining

Recovering Value from Waste: Nth Cycle's Innovative Approach

The potential inherent in waste streams is significant, as demonstrated by metals processing firm Nth Cycle. They have pioneered a technology designed to maximize the recovery of critical minerals from both mining and recycling operations.

Electro-Extraction Technology Explained

Nth Cycle’s core technology, termed “electro-extraction,” functions similarly to a water filtration system. As founder and CEO Megan O’Connor explained in a recent interview, an electrical current is applied to this filter. This current selectively isolates and extracts the desired metals.

The Importance of Metal Recovery for a Sustainable Future

Effective metal recovery and recycling are becoming increasingly vital for the electrification of the economy. Many zero-emission technologies depend on critical minerals like lithium, cobalt, nickel, and manganese. These resources, while present in the environment, are ultimately limited in quantity.

A Compact and Efficient System

Nth Cycle’s electro-extraction system occupies less than 1,000 square feet and can process five tons of material daily. This represents a significant advantage over traditional recycling methods—hydro- and pyrometallurgical techniques—which demand substantial capital investment and have a larger environmental footprint.

Processing "Black Mass" from Battery Recycling

The system is capable of accepting “black mass,” a powdery byproduct of battery recycling. It then transforms this waste material into valuable minerals, including nickel, cobalt, and manganese.

Enhancing Mining Operations

In the mining sector, Nth Cycle can be implemented at either the beginning or end of the process. It can assist companies in extracting value from low-grade sites, potentially unlocking substantial untapped mineral resources.

The company aims to facilitate the sustainable mining of resources readily available within North America.

Recovering Metals from Mining Tailings

Nth Cycle’s modular units can also process tailings—waste generated during mining operations. These units can recover up to 30% of metals that were previously left unextracted.

A Unique Business Model

Upon full commercialization, Nth Cycle intends to own and operate the processing units. Customers will retain ownership of the recovered products.

Strategic Partnerships, Not Competition

O’Connor views companies like Redwood Materials and Li-Cycle as potential partners, not competitors. Nth Cycle focuses solely on the chemical recycling aspect, specifically improving the efficiency of metal extraction from black mass.

The company is not involved in battery collection or logistics.

Reduced Capital Expenditure

Traditional hydro- and pyrometallurgical facilities can require millions of dollars in construction costs, making them inaccessible to many waste collectors. Furthermore, shipping waste to centralized recycling facilities can be impractical, particularly for low-grade materials.

“For the vast majority of distributed waste, it’s not feasible to ship it to those centralized [recycling] facilities,” O’Connor stated.

From Dissertation to Commercialization

Nth Cycle was founded the day after Megan O’Connor successfully defended her doctoral dissertation in environmental engineering at Duke University. The company was initially established as an LLC following a discussion at a Boston bar.

Support from Oak Ridge National Laboratory

Following her Ph.D., O’Connor participated in the Innovation Crossroads program at Oak Ridge National Laboratory. This two-year program supports energy and advanced manufacturing entrepreneurs. She received $500,000 in funding to scale the technology and demonstrate its potential to private investors.

Future Growth and Funding

The company is currently negotiating deals for full-scale commercial units and anticipates closing its Series A funding round in the coming months. To date, Nth Cycle has secured $1.25 million in non-dilutive grants and $3.2 million in seed funding from Clean Energy Ventures.