Probing Hybrid LiFePO4/FePO4 Phases in a Single Olive LiFePO4 Particle and Their Recovering from Degraded Electric Vehicle Batteries

Amino Group-Aided Efficient Regeneration Targeting Structural Defects and Inactive FePO4 Phase for Degraded LiFePO4 Cathodes

It is urgent to develop efficient recycling methods for spent LiFePO4 cathodes to cope with the upcoming peak of power battery retirement. Compared with the traditional metallurgical recovery methods that lack satisfactory economic and environmental benefits, the direct regeneration seems to be a promising option at present. However, a simple direct lithium replenishment cannot effectively repair and regenerate the cathodes due to the serious structural damage of the spent LiFePO4. Herein, the spent LiFePO4 cathodes are directly regenerated by a thiourea-assisted solid-phase sintering process. The density functional theory calculation indicates that thiourea has a targeted repair effect on the antisite defects and inactive FePO4 phase in the spent cathode due to the associative priority of amino group (─NH2) in thiourea with Fe ions: Fe3+─N > Fe2+─N. Meanwhile, the pyrolysis products of thiourea can also create an optimal reducing atmosphere and inhibit the agglomeration of particles in the high temperature restoration process. The regenerated LiFePO4 exhibits an excellent electrochemical performance, which is comparable to that of commercial LiFePO4. This targeted restoration has improved the efficiency of direct regeneration, which is expected to achieve large-scale recycling of spent LiFePO4.

Degradation Mechanisms of Electrodes Promotes Direct Regeneration of Spent Li-Ion Batteries: A Review

The rapid growth of electric vehicle use is expected to cause a significant environmental problem in the next few years due to the large number of spent lithium-ion batteries (LIBs). Recycling spent LIBs will not only alleviate the environmental problems but also address the challenge of limited natural resources shortages. While several hydro- and pyrometallurgical processes are developed for recycling different components of spent batteries, direct regeneration presents clear environmental, and economic advantages. The principle of the direct regeneration approach is restoring the electrochemical performance by healing the defective structure of the spent materials. Thus, the development of direct regeneration technology largely depends on the formation mechanism of defects in spent LIBs. This review systematically details the degradation mechanisms and types of defects found in diverse cathode materials, graphite anodes, and current collectors during the battery's lifecycle. Building on this understanding, principles and methodologies for directly rejuvenating materials within spent LIBs are outlined. Also the main challenges and solutions for the large-scale direct regeneration of spent LIBs are proposed. Furthermore, this review aims to pave the way for the direct regeneration of materials in discarded lithium-ion batteries by offering a theoretical foundation and practical guidance.

Toward Direct Regeneration of Spent Lithium-Ion Batteries: A Next-Generation Recycling Method

The popularity of portable electronic devices and electric vehicles has led to the drastically increasing consumption of lithium-ion batteries recently, raising concerns about the disposal and recycling of spent lithium-ion batteries. However, the recycling rate of lithium-ion batteries worldwide at present is extremely low. Many factors limit the promotion of the battery recycling rate: outdated recycling technology is the most critical one. Existing metallurgy-based recycling methods rely on continuous decomposition and extraction steps with high-temperature roasting/acid leaching processes and many chemical reagents. These methods are tedious with worse economic feasibility, and the recycling products are mostly alloys or salts, which can only be used as precursors. To simplify the process and improve the economic benefits, novel recycling methods are in urgent demand, and direct recycling/regeneration is therefore proposed as a next-generation method. Herein, a comprehensive review of the origin, current status, and prospect of direct recycling methods is provided. We have systematically analyzed current recycling methods and summarized their limitations, pointing out the necessity of developing direct recycling methods. A detailed analysis for discussions of the advantages, limitations, and obstacles is conducted. Guidance for future direct recycling methods toward large-scale industrialization as well as green and efficient recycling systems is also provided.

A Multifunctional Amino Acid Enables Direct Recycling of Spent LiFePO4 Cathode Material

Lithium iron phosphate (LiFePO4 , LFP) batteries are extensively used in electric vehicles and energy storage due to their good cycling stability and safety. However, the finite service life of lithium-ion batteries leads to significant amounts of retired LFP batteries, urgently required to be recycled by environmentally friendly and effective methods. Here, a direct regeneration strategy using natural and low-cost L-threonine as a multifunctional reductant is proposed. The hydroxyl groups and amino groups in L-threonine act as electron donors and nitrogen sources, respectively. The reductive environment created by L-threonine not only aids in converting the degraded FePO4 phase back to a single LFP phase but also facilitates the elimination of detrimental Li-Fe anti-site defects; thus, reconstructing fast Li+ diffusion channels. Meanwhile, N atoms derived from amino groups are able to dope into carbon layers, generating more active sites and enhancing the conductive properties of LFP particles. The regenerated LFP shows great electrochemical performance with a discharge capacity of 147.9 mAh g-1 at 1 C and a capacity retention of 86% after 500 cycles at 5 C. Further, this approach is also feasible for LFP black mass sourced from practical industrial dismantling lines, providing considerable prospects for the large-scale recycling of LFP batteries.