A Simple Method for the Complete Performance Recovery of Degraded Ni-rich LiNi0.70Co0.15Mn0.15O2 Cathode via Surface Reconstruction

Two birds with one stone: One-pot concurrent Ta-doping and -coating on Ni-rich LiNi0.92Co0.04Mn0.04O2 cathode materials with fiber-type microstructure and Li+-conducting layer formation

A novel scalable Taylor-Couette reactor (TCR) synthesis method was employed to prepare Ta-modified LiNi0.92Co0.04Mn0.04O2 (T-NCM92) with different Ta contents. Through experiments and density functional theory (DFT) calculations, the phase and microstructure of Ta-modified NCM92 were analyzed, showing that Ta provides a bifunctional (doping and coating at one time) effect on LiNi0.92Co0.04Mn0.04O2 cathode material through a one-step synthesis process via a controlling suitable amount of Ta and Li-salt. Ta doping allows the tailoring of the microstructure, orientation, and morphology of the primary NCM92 particles, resulting in a needle-like shape with fine structures that considerably enhance Li+ ion diffusion and electrochemical charge/discharge stability. The Ta-based surface-coating layer effectively prevented microcrack formation and inhibited electrolyte decomposition and surface-side reactions during cycling, thereby significantly improving the electrochemical performance and long-term cycling stability of NCM92 cathodes. Our as-prepared NCM92 modified with 0.2 mol% Ta (i.e., T2-NCM92) exhibits outstanding cyclability, retaining 84.5 % capacity at 4.3 V, 78.3 % at 4.5 V, and 67.6 % at 45 ℃ after 200 cycles at 1C. Even under high-rate conditions (10C), T2-NCM92 demonstrated a remarkable capacity retention of 66.9 % after 100 cycles, with an initial discharge capacity of 157.6 mAh g-1. Thus, the Ta modification of Ni-rich NCM92 materials is a promising option for optimizing NCM cathode materials and enabling their use in real-world electric vehicle (EV) applications.

Research on the facile regeneration of degraded cathode materials from spent LiNi0.5Co0.2Mn0.3O2 lithium-ion batteries

Rational reusing the waste materials in spent batteries play a key role in the sustainable development for the future lithium-ion batteries. In this work, we propose an effective and facile solid-state-calcination strategy for the recycling and regeneration of the cathode materials in spent LiNi0.5Co0.2Mn0.3O2 (NCM523) ternary lithium-ion batteries. By systemic physicochemical characterizations, the stoichiometry, phase purity and elemental composition of the regenerated material were deeply investigated. The electrochemical tests confirm that the material characteristics and performances got recovered after the regeneration process. The optimal material was proved to exhibit the excellent capacity with a discharge capacity of 147.9 mAh g-1 at 1 C and an outstanding capacity retention of 86% after 500 cycles at 1 C, which were comparable to those of commercial NCM materials.

Fundamentals, status and challenges of direct recycling technologies for lithium ion batteries

Advancement in energy storage technologies is closely related to social development. However, a significant conflict has arisen between the explosive growth in battery demand and resource availability. Facing the upcoming large-scale disposal problem of spent lithium-ion batteries (LIBs), their recycling technology development has become key. Emerging direct recycling has attracted widespread attention in recent years because it aims to 'repair' the battery materials, rather than break them down and extract valuable products from their components. To achieve this goal, a profound understanding of the failure mechanisms of spent LIB electrode materials is essential. This review summarizes the failure mechanisms of LIB cathode and anode materials and the direct recycling strategies developed. We systematically explore the correlation between the failure mechanism and the required repair process to achieve efficient and even upcycling of spent LIB electrode materials. Furthermore, we systematically introduce advanced in situ characterization techniques that can be utilized for investigating direct recycling processes. We then compare different direct recycling strategies, focussing on their respective advantages and disadvantages and their applicability to different materials. It is our belief that this review will offer valuable guidelines for the design and selection of LIB direct recycling methods in future endeavors. Finally, the opportunities and challenges for the future of battery direct recycling technology are discussed, paving the way for its further development.

Revealing Lithium Configuration in Aged Layered Oxides for Effective Regeneration

Layered oxides LiNixCoyMnzO2 are widely used as the main cathode material for high-energy lithium-ion batteries. Over long-term cycling, irreversible phase transformations in layered oxides usually occur along with the loss of active lithium, which directly reflects in the sharp decrease of capacity. However, it is difficult to accurately and rapidly determine lithium content in aged materials, raising extreme impediments in the direct recycling of layered oxides. Herein, we propose a facile method for quick and accurate calculation of the residual lithium content through the developed relationship of shear strain and the states of charge. Based on this recognization, a discharge capacity close to the original capacity of the pristine material is achieved in the regenerated material by combining a hydrothermal method with annealing treatment. The recycled material demonstrates a dramatic improvement in electrochemical properties, especially the high rate performance. This method not only effectively realizes the quantitative regeneration of cathode materials but also provides a possible strategy for the future development of direct regeneration.

A Ternary Molten Salt Approach for Direct Regeneration of LiNi0.5 Co0.2 Mn0.3 O2 Cathode

Recycling spent lithium-ion batteries (LIBs) is an urgent task in view of the resource shortage and environmental concerns. Here, a facile ternary molten salt approach is presented for efficiently regenerating the LiNi_0.5 Co_0.2 Mn_0.3 O₂ (NCM523) cathode of spent LIBs. Such an approach involves the treatment of spent cathode powder in the ternary molten salt at a moderate temperature (400 °C) and subsequent annealing in oxygen. The Li loss and degraded phases in spent NCM that cause the capacity decay can be fully remedied after the regeneration process. As a result, the regenerated cathode delivers a reversible capacity of 160 mAh g^-1 at 0.5 C with retention of 93.7% after 100 cycles and maintains a high capacity of 132 mAh g^-1 at a high rate of 5 C. The electrochemical performance of regenerated NCM cathode is compared favorably to the fresh NCM cathode, which demonstrates the feasibility of the molten salt approach to directly regenerate spent NCM cathode.

Interfacial Reviving of the Degraded LiNi0.8 Co0.1 Mn0.1 O2 Cathode by LiPO3 Repair Strategy

Nickel-rich cathode materials, owing to their high energy density and low cost, are considered to be one of the cathodes with the most potential in next-generation lithium-ion batteries. Unfortunately, this kind of cathode with highly active surface is easy to react with H₂ O and CO₂ when exposed to ambient air, resulting in the formation of lithium impurities and interfacial phase transition as well as deterioration of the electrochemical properties. In this work, the evolution mechanism of the structure and interface of LiNi_0.8 Co_0.1 Mn_0.1 O₂ during air-exposure is systematically investigated. Furthermore, a facile reviving strategy is proposed to restore the degraded LiNi_0.8 Co_0.1 Mn_0.1 O₂ by using LiPO₃ as the repair agent. The lithium impurities on the surface of the degraded sample can transform into the repair/coating layer, and part of the rock salt phase on the subsurface can revive to layered phase after repair heat treatment. As a result, the optimized cathode delivers an initial discharge capacity of 198.3 mAh g^-1 at 0.1C and a capacity retention of 85.5% after 50 cycles. Although slightly lower than the bare sample (201 mAh g^-1 and 88%), they are obviously higher than the exposed samples (166.5 mAh g^-1 and 40.4%). The regenerated electrochemical properties should be attributed to the multifunctional repair layer that can efficiently reduce the surface lithium impurities, prevent the corrosion of electrolyte, and improve the interfacial Li⁺ diffusion kinetics. This work can effectively reduce the waste of the degraded Ni-rich ternary materials and realize the transformation of "waste" into wealth.

Enhancing the interfacial stability of LiNi0.8Co0.15Al0.05O2 cathode materials by a surface-concentration gradient strategy

Ni-rich LiNi_0.8Co_0.15Al_0.05O₂ materials have been successfully applied in electric vehicles due to the merits of high energy density which can meet the requirements for driving range. Nevertheless, the electrochemical performances of Ni-rich materials are limited by their structural instability. Herein, LiNi_0.8Co_0.15Al_0.05O₂ materials with the concentration-gradient structure of a Ni-rich core and a Co-rich surface were synthesized. The electrochemical results indicate that surface-concentration gradient LiNi_0.8Co_0.15Al_0.05O₂ provides improved electrochemical performance. It not only displays an initial Coulomb efficiency of 82.4%, and a capacity retention of 80.37% after 200 cycles at 25 °C, but also shows a capacity retention of 77.76% after 150 cycles at a high temperature of 55 °C. These excellent performances can be attributed to adjusting the distribution of Ni on the surface of the LiNi_0.8Co_0.15Al_0.05O₂ material, which inhibits the interfacial reaction between the material surface and electrolyte, lowers the consumption of active Li⁺ and decreases the interfacial film impedance. Moreover, less Ni content on the material surface is beneficial for reducing the formation of a NiO rock salt phase during the charging process and inhibits the surface structural evolution. The proposed method and detected mechanism will provide guidance for the design of cathode materials and their practical industrial applications.

Insight into the Redox Reaction Heterogeneity within Secondary Particles of Nickel-Rich Layered Cathode Materials

Nickel-rich LiNi_xCo_yMn_1-x-yO₂ (nickel-rich NCM, 0.6 ≤ x < 1) cathode materials suffer from multiscale reaction heterogeneity within the electrode during the electrochemical energy storage process. However, owing to the lack of appropriate diagnostic tools, the systematic understanding and observation on the redox reaction heterogeneity at the individual secondary-particle level is still limited. Raman spectroscopy can not only reflect the depth of the redox reaction through probing the vibrational information on the metal-oxygen coordination structure but also sensitively detect the local structure changes of different regions within the secondary particle with suitable spatial resolution. Therefore, Raman spectroscopy is applied here to conveniently conduct the high-resolution and in-depth analysis of the rate-dependent reaction heterogeneity within nickel-rich NCM secondary particles. It is found that, under high-rate conditions, the oxidation/reduction reaction mainly occurs in the surface region of the particles and the cause of this particle-scale reaction heterogeneity is the limitation of the slow solid-phase Li⁺ diffusion and the transient charging/discharging processes. In addition, this reaction heterogeneity would aggravate the structural instability of the material continuously during the charging/discharging cycles, thus resulting in a slowdown in the kinetics of Li⁺ de/intercalation and the apparent capacity decay. This work can not only provide fundamental insight into the rational modification of high-power nickel-rich NCM materials but also guide the setting of electrochemical operating conditions for high-power lithium-ion batteries (LIBs).

Wet-CO2 Pretreatment Process for Reducing Residual Lithium in High-Nickel Layered Oxides for Lithium-Ion Batteries

As the push for inexpensive vehicle electrification grows, high-energy-density cathodes for lithium-ion batteries, such as high-nickel layered oxides, have received a great deal of attention in both industry and academia. These materials, however, suffer from severe residual lithium formation, which causes slurry gelation during electrode fabrication and gas evolution during cycling. Herein, a novel cobalt hydroxide coating method on wet-CO₂ gas-treated LiNi_0.91Mn_0.03Co_0.06O₂ (Co-CO₂-NMC91) is presented. Notably, the wet-CO₂ treatment prior to a dry cobalt hydroxide coating plays a critical role in improving the coating uniformity and ultimately decreases the effective residual lithium content. Furthermore, full cells of Co-CO₂-NMC91 exhibit excellent capacity retention of 91% after 200 cycles. This study highlights how a wet-CO₂ treatment can be used to improve a typical dry coating and provides new insights toward the development of cathodes for high-energy-density LIBs without severe slurry gelation or gas evolution.

A Universal Method for Enhancing the Structural Stability of Ni-Rich Cathodes Via the Synergistic Effect of Dual-Element Cosubstitution

Ni-rich layered cathodes suffer detrimental structural changes due to irreversible phase transformation (IPT). Precisely surface structural reconstruction through foreign element doping is a potential method to alleviate IPT propagation. The structure of surface reconstructed layer is greatly determined by the foreign element content and species. Herein, small doses of Ti and Al were co-substituted in LiNi_0.92Co_0.08O₂ to synergistically regulate the surface reductive Ni distribution, consequently constructing thin rock salt phase at the particle surface. This homogeneous rock salt phase combined with the strong Ti-O and Al-O bonds generated a reversible H2-H3 phase transition and further eliminated IPT propagation. Moreover, the suppressed IPT propagation converted the two-phase (H2 and H3) coexistence to a quasi-single-phase transition. This eliminated the strong internal strains caused by a significant lattice mismatch. The Ti and Al co-substituted LiNi_0.92Co_0.08O₂ exhibited outstanding capacity retention and excellent structural stability. Similar improvements were observed with W or Zr and Al cosubstitution in Ni-rich layered cathodes. This study proposes a universal method for comprehensive improvement of structural stability based on the synergistic effect of dual-element cosubstitution in Ni-rich layered oxide cathodes, which is being explored for production of high-cycle-stability lithium-ion batteries.

A green, efficient, closed-loop direct regeneration technology for reconstructing of the LiNi0.5Co0.2Mn0.3O2 cathode material from spent lithium-ion batteries

Lithium nickel manganese cobalt oxide in the spent lithium ion batteries (LIBs) contains a lot of lithium, nickel, cobalt and manganese. However, how to effectively recover these valuable metals under the premise of reducing environmental pollution is still a challenge. In this work, a green, efficient, closed-loop direct regeneration technology is proposed to reconstruct LiNi_0.5Co_0.2Mn_0.3O₂ (NCM523) cathode materials from spent LIBs. Firstly, the failure mechanism of NCM523 cathode materials in the spent LIBs is analyzed deeply. It is found that the spent NCM523 material has problems such as the dissolution of lithium and transition metals, surface interface failure and structural transformation, resulting in serious deterioration of electrochemical performance. Then NCM523 material was directly regenerated by supplementing metal ions, granulation, ion doping and heat treatment. Meanwhile, PO₄^3- polyanions were doped into the regenerated NCM material in the recovery process, showing excellent electrochemical performance with discharge capacity of 189.8 mAh g^-1 at 0.1 C. The recovery process proposed in this study puts forward a new strategy for the recovery various lithium nickel cobalt manganese oxide (e.g., LiNi_1/3Co_1/3Mn_1/3O₂, LiNi_0.5Co_0.2Mn_0.3O₂, LiNi_0.6Co_0.2Mn_0.2O₂ and LiNi_0.8Co_0.1Mn_0.1O₂) and accelerates the industrialization of spent lithium ion battery recycling.

In Situ Induced Surface Reconstruction of Single-Crystal Lithium-Ion Cathode Toward Effective Interface Compatibility

LiNi_xCo_yMn_1-x-yO₂ (x ≥ 0.5) layered oxide materials are generally considered as one of the most prospective candidates for lithium-ion battery (LIBs) cathodes due to their high specific capacity and working voltage. However, surface impurity species substantially degrade the electrochemical performance of LIBs. Herein, surface reconstruction from layered structure to disordered layer and rock-salt coherent region together with a uniform Li₂CO₃-dominant coating layer is first in situ constructed on the single-crystal LiNi_0.5Co_0.2Mn_0.3O₂ (NCM) material by a simple water treatment procedure. The unique surface structure is elucidated by Ar-sputtering-assisted X-ray photoelectron spectroscopy (XPS) and transmission electron microscopy (spherical aberration-corrected-scanning transmission electron microscopy (STEM), high-resolution transmission electron microscopy (HRTEM), and TEM). Meanwhile, neutron powder diffraction (NPD) indicates that the antisite defect concentration is mitigated in the treated materials. The modified samples display superior cycle stability with a capacity retention of up to 87.5% at 1C after 300 cycles, a high rate capacity of 151 mAh g^-1 at 5C, an elevated temperature (45 °C) cycling property with 80% capacity retention (4.5 V), and improved full-cell performance with 91% after 250 cycles at 1C. Importantly, postmortem examination on the cycled cathodes by time-of-flight secondary-ion mass spectroscopy (TOF-SIMS), XPS, TEM, and X-ray diffractometer (XRD) pattern further demonstrate that these results are mainly attributed to the thin cathode electrolyte interface (CEI) film and low solubility of transition-metal ions. Therefore, this expedition provides an opportunity to construct an effective armor for the interface compatibility and stability of LIBs.

Clean the Ni-Rich Cathode Material Surface With Boric Acid to Improve Its Storage Performance

The existence of residual lithium compounds (RLCs) on the surface of layered Ni-rich materials will deteriorate the electrochemical properties and cause safety problem. This work presents an effective surface washing method to remove the RLCs from LiNi_0.90Co_0.06Mn_0.04O₂ material surface, via ethyl alcohol solution that contains low concentration of boric acid. It is a low-cost process because the filter liquor can be recycled. The optimal parameters including washing time, boric acid concentration, and solid-liquid ratio were systematically studied. It has been determined by powder pH and Fourier transform infrared spectra results that the amount of RLCs was reduced effectively, and the storage performance was significantly enhanced for the washed samples. The 150th capacity retentions after storing had increased from 68.39% of pristine material to 85.46-94.84% of the washed materials. The performance enhancements should be ascribed to the surface washing process, which removed not only the RLCs, but also the loose primary particles effectively.

Surface regulation enables high stability of single-crystal lithium-ion cathodes at high voltage

Single-crystal cathode materials for lithium-ion batteries have attracted increasing interest in providing greater capacity retention than their polycrystalline counterparts. However, after being cycled at high voltages, these single-crystal materials exhibit severe structural instability and capacity fade. Understanding how the surface structural changes determine the performance degradation over cycling is crucial, but remains elusive. Here, we investigate the correlation of the surface structure, internal strain, and capacity deterioration by using operando X-ray spectroscopy imaging and nano-tomography. We directly observe a close correlation between surface chemistry and phase distribution from homogeneity to heterogeneity, which induces heterogeneous internal strain within the particle and the resulting structural/performance degradation during cycling. We also discover that surface chemistry can significantly enhance the cyclic performance. Our modified process effectively regulates the performance fade issue of single-crystal cathode and provides new insights for improved design of high-capacity battery materials.

Advanced Matrixes for Binder-Free Nanostructured Electrodes in Lithium-Ion Batteries

Commercial lithium-ion batteries (LIBs), limited by their insufficient reversible capacity, short cyclability, and high cost, are facing ever-growing requirements for further increases in power capability, energy density, lifespan, and flexibility. The presence of insulating and electrochemically inactive binders in commercial LIB electrodes causes uneven active material distribution and poor contact of these materials with substrates, reducing battery performance. Thus, nanostructured electrodes with binder-free designs are developed and have numerous advantages including large surface area, robust adhesion to substrates, high areal/specific capacity, fast electron/ion transfer, and free space for alleviating volume expansion, leading to superior battery performance. Herein, recent progress on different kinds of supporting matrixes including metals, carbonaceous materials, and polymers as well as other substrates for binder-free nanostructured electrodes in LIBs are summarized systematically. Furthermore, the potential applications of these binder-free nanostructured electrodes in practical full-cell-configuration LIBs, in particular fully flexible/stretchable LIBs, are outlined in detail. Finally, the future opportunities and challenges for such full-cell LIBs based on binder-free nanostructured electrodes are discussed.

Improving the Structure and Cycling Stability of Ni-Rich Layered Cathodes by Dual Modification of Yttrium Doping and Surface Coating

A crucial challenge for the commercialization of Ni-rich layered cathodes (LiNi_0.88Co_0.09Al_0.03O₂) is capacity decay during the cycling process, which originates from their interfacial instability and structural degradation. Herein, a one-step, dual-modified strategy is put forward to in situ synthesize the yttrium (Y)-doped and yttrium orthophosphate (YPO₄)-modified LiNi_0.88Co_0.09Al_0.03O₂ cathode material. It is confirmed that the YPO₄ coating layer as a good ion conductor can stabilize the solid-electrolyte interface, while the formative strong Y-O bond can bridle TM-O slabs to intensify the lattice structure in the state of deep delithium (>4.3 V). In particular, both the combined advantages effectively withstand the anisotropic strain generated upon the H2-H3 phase transition and further alleviate the crack generation in unit-cell dimensions, assuring a high-capacity delivery and fast Li⁺ diffusion kinetics. This dual-modified cathode shows advanced cycling stability (94.1% at 1C after 100 cycles in 2.7-4.3 V), even at a high cutoff voltage and high rate, and advanced rate capability (159.7 mAh g^-1 at 10C). Therefore, it provides a novel solution to achieve both high capacity and highly stable cyclability in Ni-rich cathode materials.