Emerging Trends and Future Opportunities for Battery Recycling

The global lithium-ion battery recycling capacity needs to increase by a factor of 50 in the next decade to meet the projected adoption of electric vehicles. During this expansion of recycling capacity, it is unclear which technologies are most appropriate to reduce costs and environmental impacts. Here, we describe the current and future recycling capacity situation and summarize methods for quantifying costs and environmental impacts of battery recycling methods with a focus on cathode active materials. Second use, electrification of pyrometallurgy and hydrometallurgy, direct recycling, and electrochemical recycling methods are discussed as leading-edge methods for overcoming state of the art battery recycling challenges. The paper ends with a discussion of future issues and considerations regarding solid-state batteries and co-optimization of battery design for recycling.

Biobased Acrylic Latexes/Sodium Carboxymethyl Cellulose Aqueous Binders for Lithium-Ion NMC 811 Cathodes

The increasing demands for sustainable energy storage technologies have prompted extensive research in the development of eco-friendly materials for lithium-ion batteries (LIBs). This research article presents the design of biobased latexes, which are fluorine-free and rely on renewable resources, based on isobornyl methacrylate (IBOMA) and 2-octyl acrylate (2OA) to be used as binders in batteries. Three different compositions of latexes were investigated, varying the ratio of IBOMA and 2OA: (1) Poly2OA homopolymer, (2) Poly(2OA0,6-co-IBOMA0,4) random copolymer, and (3) PolyIBOMA homopolymer. The combination of the two monomers provided a balance between rigidity from the hard monomer (IBOMA) and flexibility from the soft one (2OA). The study evaluated the performance of the biobased latexes using sodium carboxymethyl cellulose (CMC) as a thickener and cobinder by fabricating LiNi0.8Mn0.1Co0.1O2 (NMC 811) cathodes. Also, to compare with the state of the art, organic processed PVDF electrodes were prepared. Among aqueous slurries, rheological analysis showed that the CMC + Poly(2OA0,6-co-IBOMA0,4) binder system resulted in the most stable and well-dispersed slurries. Also, the electrodes prepared with this latex demonstrated enhanced adhesion (210 ± 9 N m-1) and reduced cracks compared to other aqueous compositions. Electrochemical characterization revealed that the aqueous processed cathodes using the CMC + Poly(2OA0,6-co-IBOMA0,4) biobased latex displayed higher specific capacities than the control with no latex at high C-rates (100.3 ± 2.1 vs 64.5 ± 0.8 mAh g-1 at 5C) and increased capacity retention after 90 cycles at 0.5C (84% vs 81% for CMC with no latex). Overall, the findings of this study suggest that biobased latexes, specifically the CMC + Poly(2OA0,6-co-IBOMA0,4) composition, are promising as environmentally friendly binders for NMC 811 cathodes, contributing to the broader goal of achieving sustainable energy storage systems.

A Polytetrafluoroethylene-Based Solvent-Free Procedure for the Manufacturing of Lithium-Ion Batteries

Lithium-ion batteries (LIBs) have recently become popular for energy storage due to their high energy density, storage capacity, and long-term cycle life. Although binders make up only a small proportion of LIBs, they have become the key to promoting the transformation of the battery preparation process. Along with the development of binders, the battery manufacturing process has evolved from the conventional slurry-casting (SC) process to a more attractive solvent-free (SF) method. Compared with traditional LIBs manufacturing method, the SF method could dramatically reduce and increase the energy density due to the reduced preparation steps and enhanced electrode loading. Polytetrafluoroethylene (PTFE), as a typical binder, has played an important role in fabricating high-performance LIBs, particularly in regards to the SF technique. In this paper, the development history and application status of PTFE binder was introduced, and then its contributions and the inherent problems involved in the SF process were described and analyzed. Finally, the viewpoints concerning the future trends for PTFE-based SF manufacturing methods were also discussed. We hope this work can inspire future research concerning high-quality SF binders and assist in promoting the evolution of the SF manufacturing technology in regards to LIBs.

Carrageenans as Sustainable Water-Processable Binders for High-Voltage NMC811 Cathodes

Poly(vinylidene fluoride) (PVDF) is the most common binder for cathode electrodes in lithium-ion batteries. However, PVDF is a fluorinated compound and requires toxic N-methyl-2-pyrrolidone (NMP) as a solvent during the slurry preparation, making the electrode fabrication process environmentally unfriendly. In this study, we propose the use of carrageenan biopolymers as a sustainable source of water-processable binders for high-voltage NMC811 cathodes. Three types of carrageenan (Carr) biopolymers were investigated, with one, two, or three sulfonate groups (SO3-), namely, kappa, iota, and lambda carrageenans, respectively. In addition to the nature of carrageenans, this article also reports the optimization of the cathode formulations, which were prepared by using between 5 wt % of the binder to a lower amount of 2 wt %. Processing of the aqueous slurries and the nature of the binder, in terms of the morphology and electrochemical performance of the electrodes, were also investigated. The Carr binder with 3SO3- groups (3SO3-Carr) exhibited the highest discharge capacities, delivering 133.1 mAh g-1 at 3C and 105.0 mAh g-1 at 5C, which was similar to the organic-based PVDF electrode (136.1 and 108.7 mAh g-1, respectively). Furthermore, 3SO3-Carr reached an outstanding capacity retention of 91% after 90 cycles at 0.5C, which was attributed to a homogeneous NMC811 and a conductive carbon particle dispersion, superior adhesion strength to the current collector (17.3 ± 0.7 N m-1 vs 0.3 ± 0.1 N m-1 for PVDF), and reduced charge-transfer resistance. Postmortem analysis unveiled good preservation of the NMC811 particles, while the 1SO3-Carr and 2SO3-Carr electrodes showed damaged morphologies.

Do eco-friendly binders affect the electrochemical performance of MOF@CNT anodes in lithium-ion batteries?

We substituted an organic-based binder with a natural water-soluble binder (CMC) in the anode of a lithium-ion battery.