Reaction-passivation mechanism driven materials separation for recycling of spent lithium-ion batteries

Chemical-Free Recycling of Cathode Material and Aluminum Foil from Waste Lithium-Ion Batteries by Combining Plasma and Ultrasonic Technology

With the rapid demand for lithium-ion batteries due to the widespread application of electric vehicles, a significant amount of battery electrode pieces requiring urgent treatment are generated during battery production and disposal. The strong bonding caused by the presence of binders makes it challenging to achieve thorough separation between the cathode active materials and Al foil, posing difficulties in efficient battery material recycling. To address this issue, a plasma-ultrasonically combined physical separation method is proposed in this study. This method utilizes plasma-generated excited-state radicals assisted by ultrasonic waves to separate active materials and current collectors. The results indicate that the binders are effectively decomposed under plasma treatment at 13.56 MHz, 100 W, and 10 min in an oxygen atmosphere, resulting in a separation efficiency of 96.8 wt % for the cathode materials. Characterization results demonstrate that the morphology, crystal structure, and chemical composition of the recycled cathode active materials remain unchanged, facilitating subsequent direct restoration and hydrometallurgical recycling. Simultaneously, the Al foil is also completely recycled for subsequent reuse. Compared with traditional methods of separating cathode active materials and aluminum foil, the method proposed in this study has significant economic and environmental potential. It can promote the recycling of battery materials and the development of sustainable transportation.

Gel polymer electrolytes for rechargeable batteries toward wide-temperature applications

Rechargeable batteries, typically represented by lithium-ion batteries, have taken a huge leap in energy density over the last two decades. However, they still face material/chemical challenges in ensuring safety and long service life at temperatures beyond the optimum range, primarily due to the chemical/electrochemical instabilities of conventional liquid electrolytes against aggressive electrode reactions and temperature variation. In this regard, a gel polymer electrolyte (GPE) with its liquid components immobilized and stabilized by a solid matrix, capable of retaining almost all the advantageous natures of the liquid electrolytes and circumventing the interfacial issues that exist in the all-solid-state electrolytes, is of great significance to realize rechargeable batteries with extended working temperature range. We begin this review with the main challenges faced in the development of GPEs, based on extensive literature research and our practical experience. Then, a significant section is dedicated to the requirements and design principles of GPEs for wide-temperature applications, with special attention paid to the feasibility, cost, and environmental impact. Next, the research progress of GPEs is thoroughly reviewed according to the strategies applied. In the end, we outline some prospects of GPEs related to innovations in material sciences, advanced characterizations, artificial intelligence, and environmental impact analysis, hoping to spark new research activities that ultimately bring us a step closer to realizing wide-temperature rechargeable batteries.

Dynamic Li+ Capture through Ligand-Chain Interaction for the Regeneration of Depleted LiFePO4 Cathode

After application in electric vehicles, spent LiFePO4 (LFP) batteries are typically decommissioned. Traditional recycling methods face economic and environmental constraints. Therefore, direct regeneration has emerged as a promising alternative. However, irreversible phase changes can significantly hinder the efficiency of the regeneration process owing to structural degradation. Moreover, improper storage and treatment practices can lead to metamorphism, further complicating the regeneration process. In this study, a sustainable recovery method is proposed for the electrochemical repair of LFP batteries. A ligand-chain Zn-complex (ZnDEA) is utilized as a structural regulator, with its ─NH─ group alternatingly facilitating the binding of preferential transition metal ions (Fe3+ during charging and Zn2+ during discharging). This dynamic coordination ability helps to modulate volume changes within the recovered LFP framework. Consequently, the recovered LFP framework can store more Li-ions, enhance phase transition reversibility between LFP and FePO4 (FP), modify the initial Coulombic efficiency, and reduce polarization voltage differences. The recovered LFP cells exhibit excellent capacity retention of 96.30% after 1500 cycles at 2 C. The ligand chain repair mechanism promotes structural evolution to facilitate ion migration, providing valuable insights into the targeted ion compensation for environmentally friendly recycling in practical applications.

10 μm-Level TiNb2 O7 Secondary Particles for Fast-Charging Lithium-Ion Batteries

TiNb2 O7 with Wadsley-Roth phase delivers double theoretical specific capacity and similar working potential in comparison to spinel Li4 Ti5 O12 , the commercial high-rate anode material, and thus can enable much higher energy density of lithium-ion batteries. However, the inter-particle resistance within the high-mass-loading TiNb2 O7 electrode would impede the capacity release for practical application, especially under fast-charging conditions. Herein, 10-20 μm-size carbon-coated TiNb2 O7 secondary particle (SP-TiNb2 O7 ) consisting of initial micro-scale TiNb2 O7 particles (MP-TiNb2 O7 ) was fabricated. The high crystallinity of active material could enable fast-charge diffusion and electrochemical reaction rate within particles, and the small number of stacking layers of SP-TiNb2 O7 could reduce the large inter-particle resistance that regular particle electrode often possess and achieve high compaction density of electrodes with high mass loading. The investigation on materials structure and electrochemical reaction kinetics verified the advances of the as-fabricated SP-TiNb2 O7 in achieving superior electrochemical performance. The SP-TiNb2 O7 exhibited high reversible capacity of 292.7 mAh g-1 in the potential range of 1-3 V (Li+ /Li) at 0.1 C, delivering high-capacity release of 94.3 %, and high capacity retention of 86 % at 0.5 C for 250 cycles in half cell configuration. Particularly, the advances of such an anode were verified in practical 5 Ah-level laminated full pouch cell. The as-assembled LiFePO4 ||TiNb2 O7 full cell exhibited a high capacity of 5.08 Ah at high charging rate of 6 C (77.9 % of that at 0.2 C of 6.52 Ah), as well as an ultralow capacity decay rate of 0.0352 % for 250 cycles at 1 C, suggesting the great potential for practical fast-charging lithium-ion batteries.