Efficient Nanostructuring of Silicon by Electrochemical Alloying/Dealloying in Molten Salts for Improved Lithium Storage

Molten Salt-Assisted Synthesis of Catalysts for Energy Conversion

A breakthrough in manufacturing procedures often enables people to obtain the desired functional materials. For the field of energy conversion, designing and constructing catalysts with high cost-effectiveness is urgently needed for commercial requirements. Herein, the molten salt-assisted synthesis (MSAS) strategy is emphasized, which combines the advantages of traditional solid and liquid phase synthesis of catalysts. It not only provides sufficient kinetic accessibility, but effectively controls the size, morphology, and crystal plane features of the product, thus possessing promising application prospects. Specifically, the selection and role of the molten salt system, as well as the mechanism of molten salt assistance are analyzed in depth. Then, the creation of the catalyst by the MSAS and the electrochemical energy conversion related application are introduced in detail. Finally, the key problems and countermeasures faced in breakthroughs are discussed and look forward to the future. Undoubtedly, this systematical review and insights here will promote the comprehensive understanding of the MSAS and further stimulate the generation of new and high efficiency catalysts.

A Mechanochemically-Triggered, Self-Powered Flash Heating Synthesis of Phosphorous/Caron Composites for Li-Ion Batteries

"Flash heating" that transiently generates high temperatures above 1000 °C has great potential in synthesizing new materials with unprecedently properties. Up to now, the realization of "flash heating" still relies on the external power, which requires sophisticated setups for vast energy input. In this study, a mechanochemically triggered, self-powered flash heating approach is proposed by harnessing the enthalpy from chemical reactions themselves. Through a model reaction between Mg3N2/carbon and P2O5, it is demonstrated that this self-powered flash heating is controllable and compatible with conventional devices. Benefit from the self-powered flash heating, the resulting product has a nanoporous structure with a uniform distribution of phosphorus (P) nanoparticles in carbon (C) nanobowls with strong P─-C bonds. Consequently, the P/C composite demonstrates remarkable energy storage performance in lithium-ion batteries, including high capacity (1417 mAh g-1 at 0.2 A g-1), robust cyclic stability (935 mAh g-1 at 2 A g-1 after 800 cycles, 91.6% retention), high-rate capability (739 mAh g-1 at 20 A g-1), high loading performance (3.6 mAh cm-2 after 100 cycles), and full cell cyclic stability (90% retention after 100 cycles). This work broadens the flash heating concept and can potentially find application in various fields.

Self-Assembly of Silicon Nanotubes Driven by a Biphasic Transition from the Natural Mineral Montmorillonite in Molten Salt Electrolysis

Silicon nanotubes (SNTs) have been considered as promising anode materials for lithium-ion batteries (LIBs). However, the reported strategies for preparing SNTs generally have special requirements for either expensive templates or complex catalysts. It is necessary to explore a cost-effective and efficient approach for the preparation of high-performance SNTs. In this work, a biphasic transformation strategy involving "solid-state reduction" and "dissolution-deposition" in molten salts is developed to prepare SNTs using montmorillonite as a precursor. The rod-like intermediate of silicon-aluminum-calcium is initially reduced in solid state, which then triggers the continuous dissolution and deposition of calcium silicate in the inner space of the intermediate to form a hollow structure during the subsequent reduction process. The transition from solid to liquid is crucial for improving the kinetics of deoxygenation and induces the self-assembly of SNTs during electrolysis. When the obtained SNTs is used as anode materials for LIBs, they exhibit a high capacity of 2791 mAh g-1 at 0.2 A g-1, excellent rate capability of 1427 mA h g-1 at 2 A g-1, and stable cycling performance with a capacity of 2045 mAh g-1 after 200 cycles at 0.5 A g-1. This work provides a self-assembling, controllable, and cost-effective approach for fabricating SNTs.

Single-Atom Ni Supported on TiO2 for Catalyzing Hydrogen Storage in MgH2

As an efficient and clean energy carrier, hydrogen is expected to play a key role in future energy systems. However, hydrogen-storage technology must be safe with a high hydrogen-storage density, which is difficult to achieve. MgH2 is a promising solid-state hydrogen-storage material owing to its large hydrogen-storage capacity (7.6 wt %) and excellent reversibility, but its large-scale utilization is restricted by slow hydrogen-desorption kinetics. Although catalysts can improve the hydrogen-storage kinetics of MgH2, they reduce the hydrogen-storage capacity. Single-atom catalysts maximize the atom utilization ratio and the number of interfacial sites to boost the catalytic activity, while easy aggregation at high temperatures limits further application. Herein, we designed a single-atom Ni-loaded TiO2 catalyst with superior thermal stability and catalytic activity. The optimized 15wt%-Ni0.034@TiO2 catalyst reduced the onset dehydrogenation temperature of MgH2 to 200 °C. At 300 °C, the H2 released and absorbed 4.6 wt % within 5 min and 6.53 wt % within 10 s, respectively. The apparent activation energies of MgH2 dehydrogenation and hydrogenation were reduced to 64.35 and 35.17 kJ/mol of H2, respectively. Even after 100 cycles of hydrogenation and dehydrogenation, there was still a capacity retention rate of 97.26%. The superior catalytic effect is attributed to the highly synergistic catalytic activity of single-atom Ni, numerous oxygen vacancies, and multivalent Tix+ in the TiO2 support, in which the single-atom Ni plays the dominant role, accelerating electron transfer between Mg2+ and H- and weakening the Mg-H bonds. This work paves the way for superior hydrogen-storage materials for practical unitization and also extends the application of single-atom catalysis in high-temperature solid-state reactions.

Stratum-Confined Solid-State Reaction (SC-SSR) toward Colloidal Silicon-Based Hollow Nanostructures for Bioapplications

Silicon nanostructures (SiNSs) can provide multifaceted bioapplications; but preserving their subhundred nm size during high-temperature silica-to-silicon conversion is the major bottleneck. The SC-SSR utilizes an interior metal-silicide stratum space at a predetermined radial distance inside silica nanosphere to guide the magnesiothermic reduction reaction (MTR)-mediated synthesis of hollow and porous SiNSs. In depth mechanistic study explores solid-to-hollow transformation encompassing predefined radial boundary through the participation of metal-silicide species directing the in-situ formed Si-phase accumulation within the narrow stratum. Evolving thin-porous Si-shell remains well protected by the in-situ segregated MgO emerging as a protective cast against the heat-induced deformation and interparticle sintering. Retrieved hydrophilic SiNSs (<100 nm) can be conveniently processed in different biomedia as colloidal solutions and endocytosized inside cells as photoluminescence (PL)-based bioimaging probes. Inside the cell, rattle-like SiNSs encapsulated with Pd nanocrystals can function as biorthogonal nanoreactors to catalyze intracellular synthesis of probe molecules through C-C cross coupling reaction.

Molten salt method synthesis of multivalent cobalt and oxygen vacancy modified Nitrogen-doped MXene as highly efficient hydrogen and oxygen Evolution reaction electrocatalysts

Nitrogen-doped Ti₃C₂T_y MXene with multivalent cobalt and oxygen vacancy (Vo) modification was obtained by using molten salt method and greatly improved electrocatalytic performance. The structural properties of MXene and the valence state of cobalt were adjusted by controlling the molten salt temperature. When the molten salt treatment temperature was 377 °C, the obtained 377-CoO_xN_1-x-Ti₃C₂T_y maintained the chemical structure of MXene well, and also has high Co²⁺ content and Vo content. Electrochemical test results showed that 377-CoO_xN_1-x-Ti₃C₂T_y had the lowest Hydrogen Evolution Reaction (HER) overpotential of 87.73 mV and good electrocatalytic stability. X-ray Photoelectron Spectroscopy (XPS) results and Density Functional Theory (DFT) calculations showed that the introduction of polyvalent cobalt and Vo in the nitrogen-doped Ti₃C₂T_y structure effectively reduced the energy barrier of the electrocatalytic reaction of MXene.

Flux upcycling of spent NMC 111 to nickel-rich NMC cathodes in reciprocal ternary molten salts

The proper handling of end-of-life (EOL) lithium-ion batteries (LIBs) has become an urgent and challenging issue with the surging use of LIBs, in which recovering high-value cathodes not only relieves the pressure on the raw material supply chain but also minimizes environmental pollution. Beyond direct recycling of spent cathodes to their pristine states, the direct upcycling of spent cathodes to the next-generation cathodes is of great significance to maximize the value of spent materials and to sustain the fast development of LIBs. Herein, a “reciprocal ternary molten salts” (RTMS) system was developed to directly upcycle spent NMC 111 to Ni-rich NMCs by simultaneously realizing the addition of Ni and the relithiation of Li in spent NMC 111. After RTMS flux upcycling, the obtained Ni-rich NMCs exhibited an α-NaFeO₂-type layered structure, restored Li content, and excellent performance, which is very similar to that of the pristine NMC 622.

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A “reciprocal ternary molten salts” (RTMS) system is developed for upcycling

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Directly upcycling of spent NMC 111 to Ni-rich NMC (NMC 622) is realized in air

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RTMS provides the Li source and a flux oxygen-rich environment for upcycling

In-situ anodic precipitation process for highly efficient separation of aluminum alloys

Electrorefining process has been widely used to separate and purify metals, but it is limited by deposition potential of the metal itself. Here we report in-situ anodic precipitation (IAP), a modified electrorefining process, to purify aluminium from contaminants that are more reactive. During IAP, the target metals that are more cathodic than aluminium are oxidized at the anode and forced to precipitate out in a low oxidation state. This strategy is fundamentally based on different solubilities of target metal chlorides in the NaAlCl₄ molten salt rather than deposition potential of metals. The results suggest that IAP is able to efficiently and simply separate components of aluminum alloys with fast kinetics and high recovery yields, and it is also a valuable synthetic approach for metal chlorides in low oxidation states.

Traditional electrorefining process is limited by deposition potential of the metal itself. Here, the authors explore an in-situ anodic precipitation process based on different solubility of target metal chlorides that can efficiently separate components of aluminum alloys.

Template-Free Electrochemical Formation of Silicon Nanotubes from Silica

Silicon, with its elaborate microstructure, plays important roles in energy materials. In operando engineering of microstructure during extraction is an ideal protocol to develop advanced Si-based materials. A template-free electrochemical preparation of silicon nanotubes (Si-NT) is herein achieved by co-electrolysis of SiO2 and AgCl in molten NaCl-CaCl2 at 850 °C. The in situ electrodeposited Ag facilitates the generation of a liquid Ag-Si intermediate, triggering a liquid-solid mechanism to direct the growth of Si-NT. An automatic separation of Ag from Si then occurs in the following cooling process, resulting in Ag deposits on the Ni current collector and recycling of Ag. Such a facile and smart preparation of Si-NT from affordable silica guarantees an enhanced current efficiency of 74%, a decreased energy consumption of 12.1 kW h kgSi -1, and enhanced lithium-storage capability of the electrolytic Si-NT. An in situ coating of Ag over the Si-NT can also be fulfilled by simply introducing soluble AgCl in the melts. The present study provides a template-free preparation and an in situ surface modification of Si-NT.

Direct Conversion of Rice Husks to Nanostructured SiC/C for CO2 Photoreduction

A one-step and template-free synthesis of a SiC nanowires/C (SiC-NW/C) composite from rice husks (RHs) is realized via a molten-salt-assisted electrochemical method. The process integrates simultaneously carbonization, electrodeoxidation, nanostructuring, and self-purification for converting RHs to a SiC-NW/C hybrid that is assembled from SiC NWs embedded in porous N-doped graphitic carbon with strong coupling. The SiC-NW/C nanostructure enables efficient CO₂ adsorption and fast separation and transfer of charge carriers. Benefiting from the structural and compositional merits, the SiC-NW/C composite shows superior activity for photoreduction of CO₂ to CO, in the absence of any additional cocatalysts or sacrificial agents. The process proposed herein might help to bridge a closed-loop carbon cycle in the whole production-utilization of biomass.

Mechanically Reinforced Localized Structure Design to Stabilize Solid-Electrolyte Interface of the Composited Electrode of Si Nanoparticles and TiO2 Nanotubes

Silicon anode with extremely high theoretical specific capacity (≈4200 mAh g^-1 ), experiences huge volume changes during Li-ion insertion and extraction, causing mechanical fracture of Si particles and the growth of a solid-electrolyte interface (SEI), which results in a rapid capacity fading of Si electrodes. Herein, a mechanically reinforced localized structure is designed for carbon-coated Si nanoparticles (C@Si) via elongated TiO₂ nanotubes networks toward stabilizing Si electrode via alleviating mechanical strain and stabilizing the SEI layer. Benefited from the rational localized structure design, the carbon-coated Si nanoparticles/TiO₂ nanotubes composited electrode (C@Si/TiNT) exhibits an ideal electrode thickness swelling, which is lower than 1% after the first cycle and increases to about 6.6% even after 1600 cycles. While for traditional C@Si/carbon nanotube composited electrode, the initial swelling ratio is about 16.7% and reaches ≈190% after 1600 cycles. As a result, the C@Si/TiNT electrode exhibits an outstanding capacity of 1510 mAh g^-1 at 0.1 A g^-1 with high rate capability and long-time cycling performance with 95% capacity retention after 1600 cycles. The rational design on mechanically reinforced localized structure for silicon electrode will provide a versatile platform to solve the current bottlenecks for other alloyed-type electrode materials with large volume expansion toward practical applications.

Engineering Carbon Distribution in Silicon-Based Anodes at Multiple Scales

The successful commercialization of promising silicon-based anode materials has been hampered by their poor cycling stability caused by the huge volume change. Integration of the carbon matrix with silicon-based (C/Si-based) anode materials has been demonstrated to be a powerful solution to achieve satisfactory electrochemical performance. This minireview aims to outline recent developments on C/Si-based composites, with the emphasis on the importance of carbon distribution at multiple scales. In addition, the forms of the carbon framework (carbon sources and doping of heteroatoms) have been summarized. Particularly, a novel C/Si-based hybrid with carbon distributed at the atomic scale has been highlighted.

Layer-by-Layer Engineered Silicon-Based Sandwich Nanomat as Flexible Anode for Lithium-Ion Batteries

Lithium-ion batteries with high electrochemical performance and stable mechanical compliance are pivotal to propel the advanced wearable electronics forward. Herein, a high-conductive flexible electrode densified from multilayer lamellar unit cells with the silicon-based sandwich structure is rationally designed by molecular engineering. Silicon nanoparticles can be uniformly anchored to the surface of 2,2,6,6-tetramethylpiperidine-1-oxyl (TEMPO)-oxidized bacterial cellulose (TOBC) aerogel through hydrogen bonding, which effectively relaxes the drastic volume expansion of the Si-based anode. The graphite microsheets (GMs) attached on silicon nanoparticles allow the porous aerogel network to maintain excellent electrical connection in all directions, and after being switched to compact film, the conductive network enables a robust contact with silicon nanoparticles. As a result, the Si-based nanomat anode exhibits reliable cycling stability (639.4 mA h g^-1 after 400 cycles at 1.0 A g^-1) and enhanced rate capability (298.6 mA h g^-1 at 1.6 A g^-1). Notably, instead of conventional polyolefin separators, TOBC-reinforced silica aerogel is fabricated as an advanced separator to integrate the flexible all-in-one full-cell with freestanding GM/TOBC/silicon (GM/TOBC/Si) anode and GM/TOBC/LiFePO₄ cathode. Driven by the unique structure and functional component, the flexible all-in-one lithium-ion batteries showcase exceptional deformation tolerance yet impressive charge/discharge behavior.

Atomic Pt Promoted N-Doped Carbon as Novel Negative Electrode for Li-Ion Batteries

In this work, platinum single-atom enhanced mushroom-based carbon (Pt₁/MC) materials have been facilely synthesized and served as novel electrode materials in lithium-ion batteries (LIBs). The as-synthesized Pt₁/MC active material shows a uniform dispersion of isolated Pt atoms on an MC support with high specific surface area and large total pore volume. As a negative electrode material for LIBs, the Pt₁/MC exhibits excellent electrochemical properties, which retains a capacity of 846 mA h g^-1 after 800 cycles at 2 A g^-1 and 349 mA h g^-1 (near to the theoretical capacity of graphite) after 6000 cycles at a high current density of 5 A g^-1. The remarkable high capacity and excellent cycling stability can be attributed to their porous nanostructures and atomic-Pt-enhanced lithium-ion storage. Atomic Pt can compound with Li⁺ ions to form a platinum-lithium alloy during the discharge and charge process. Density functional theory (DFT) calculations are performed to verify that the PtLi₅ alloy is the most stable intermedium on the MC substrate, which further enhances the lithiation and delithiation kinetics. This novel perspective is helpful to explore next-generation negative electrode materials with high capacities and good stabilities for LIBs.

In Situ Pyrolysis Concerted Formation of Si/C Hybrids during Molten Salt Electrolysis of SiO2@Polydopamine

Aiming to enhanced productivity and improved functionality of electrolytic silicon from electroreduction of solid silica in molten salts, we herein report a one-pot electrochemical preparation of Si/C hybrids via pyrolysis-cum-electrolysis (PCE) of SiO₂@polydopamine (SiO₂@PDA) in molten NaCl-CaCl₂ at 800 °C. The obtained hybrids, denoted Si@C@Si, are composed of outmost silicon thin layers due to electrodeposition, sandwiched N-doped carbon hollow spheres derived from pyrolysis of PDA, and encapsulated silicon nanoparticles stemming from direct electrodeoxidation of SiO₂. The PCE protocol shows intriguing merits on accelerated electroreduction of SiO₂ and retarded generation of inconvenient SiC. The preparation conditions of Si@C@Si are optimized by varying electrolysis time and applied voltage, with the optimal conditions being identified as PCE at 2.6 V for 2 h. When evaluated as an anode for lithium-ion batteries, the obtained Si@C@Si exhibits a reversible specific capacity of 904 mAh g^-1 after 100 galvanostatic charge/discharge cycles at 500 mA g^-1. The proposed PCE method is highlighted as an intensified Si extraction method for advanced lithium-ion batteries, promising practical applications.

Encapsulation of core–satellite silicon in carbon for rational balance of the void space and capacity

A novel core–satellite architecture with an elaborate structural design for rational balance of the void space and capacity.