Cleaner separation and recovery of valuable metals from spent ternary cathode via carbon dioxide synergetic thermite reduction strategy.

The low-carbon recycling of spent lithium-ion batteries has become crucial due to the increasing need to address resource shortages and environmental concerns. Herein, a low-carbon, facile, and efficient method was developed to separate and recover Li, Al, and transition metals from spent ternary cathodes. Initially, the cathode materials post-discharge and disassembly do not require pre-sorting. Instead of using carbonaceous materials, the Al foil in the cathode serves as the reducing agent during reduction roasting. The impact of different roasting atmospheres (air, N2, CO2) on phase transitions and the extraction of valuable metals was examined. The findings revealed that after synergistic thermite reduction in a carbon dioxide atmosphere, the cathode material is completely dissociated. Li is selectively converted to Li2CO3 rather than LiAlO2, and the reduced reactivity of the Al foil encourages the formation of lower-valence oxides of Ni and Co, rather than their metallic forms. Under optimal roasting conditions at 650 °C for 1.0 h, 91.4% of Li can be preferentially and selectively extracted through carbonation water leaching, with less than 0.1% of Al and transition metals dissolving. Subsequently, ∼98% of Al and ∼99% of Ni, Co, and Mn can be leached using alkaline and acidic solutions, respectively. Compared to the traditional carbon thermal reduction process, this process offers several advantages including the elimination of pre-sorting and additional reducing agents, lower carbon emissions, and higher recovery rates of valuable metals. Thus, this process makes the recovery of metals from spent lithium-ion batteries more environmentally sustainable, simple, cost-effective, and adaptable.

Regulating Anode-electrolyte Interphasial Reactions by Zwitterionic Binder Chemistry in Lithium-ion Batteries with High-nickel Layered Oxide Cathodes and Silicon-Graphite Anodes.

The practical application of silicon (Si)-based anodes faces challenges due to severe structural and interphasial degradations. These challenges are exacerbated in lithium-ion batteries (LIBs) employing Si-based anodes with high-nickel layered oxide cathodes, as significant transition-metal crossover catalyzes serious parasitic side reactions, leading to faster cell failure. While enhancing the mechanical properties of polymer binders has been acknowledged as an effective means of improving solid-electrolyte interphase (SEI) stability on Si-based anodes, an in-depth understanding of how the binder chemistry influences the SEI is lacking. Herein, a zwitterionic binder with an ability to manipulate the chemical composition and spatial distribution of the SEI layer is designed for Si-based anodes. It is evidenced that the electrically charged microenvironment created by the zwitterionic species alters the solvation environment on the Si-based anode, featuring rich anions and weakened Li+-solvent interactions. Such a binder-regulated solvation environment induces a thin, uniform, robust SEI on Si-based anodes, which is found to be the key to withstanding transition-metal deposition and minimizing their detrimental impact on catalyzing electrolyte decomposition and devitalizing bulk Si. As a result, albeit possessing comparable mechanical properties to those of commercial binders, the zwitterionic binder enables superior cycling performances in high-energy-density LIBs under demanding operating conditions.

Enhancing Lithium-Ion Battery Health Predictions by Hybrid-Grained Graph Modeling.

Predicting the health status of lithium-ion batteries is crucial for ensuring safety. The prediction process typically requires inputting multiple time series, which exhibit temporal dependencies. Existing methods for health status prediction fail to uncover both coarse-grained and fine-grained temporal dependencies between these series. Coarse-grained analysis often overlooks minor fluctuations in the data, while fine-grained analysis can be overly complex and prone to overfitting, negatively impacting the accuracy of battery health predictions. To address these issues, this study developed a Hybrid-grained Evolving Aware Graph (HEAG) model for enhanced prediction of lithium-ion battery health. In this approach, the Fine-grained Dependency Graph (FDG) helps us model the dependencies between different sequences at individual time points, and the Coarse-grained Dependency Graph (CDG) is used for capturing the patterns and magnitudes of changes across time series. The effectiveness of the proposed method was evaluated using two datasets. Experimental results demonstrate that our approach outperforms all baseline methods, and the efficacy of each component within the HEAG model is validated through the ablation study.

Diagnostic Protocols for Evaluating the Degradation Mechanisms in Gel-Polymer Lithium Batteries.

Gel polymer electrolytes (GPEs) present a promising alternative to standard liquid electrolytes (LE) for Lithium-ion Batteries (LIBs) and Lithium Metal Batteries bridging the advantages of both liquid and solid polymer electrolytes. However, their cycle life still lags behind that of standard LIBs, and their degradation mechanisms remain poorly understood. A significant challenge is the need for specific diagnostic protocols to systematically study the degradation mechanisms of GPE-based cells. Challenges include the separation of cell components and effective washing, as well as the study of the solid electrolyte interfaces, all complicated by the semi-solid nature of GPEs. This paper provides a brief review of existing literature and proposes a comprehensive set of diagnostic tools for dismantling and evaluating the degradation of GPE-based LIBs. Finally, these methods and recommendations are applied to LiNi0.5Mn1.5O4 (LNMO)-graphite cells, revealing electrolyte oxidation as a major source of cell degradation.

Enhanced mechanical and surface chemical stability in cobalt-free, high-nickel cathode materials for lithium-ion batteries.

Cobalt-free, high-nickel cathode materials are essential for the sustainable evolution of energy storage technologies, reducing the dependence on resources with significant environmental and social implications and simultaneously improving the efficiency and cost effectiveness of batteries. This paper introduces a cobalt-free, high-nickel cathode material called 0.01B-LiNi0.98Mg0.01Zr0.01O2 (NMZB) developed using a novel blend of elements to enhance mechanical and surface chemical stability. Detailed evaluations confirmed the successful integration of Mg, Zr, and B into the particles, with Mg and Zr primarily located within the particle interior and B predominantly on the surface. This unique elemental configuration significantly improves the stability of the bulk phase and surface structure of the material. In addition, the refinement of primary particles within NMZB further enhances its mechanical stability. As a result, NMZB exhibits exceptional electrochemical stability, achieving 90.5 % capacity retention after 200 cycles at a 1C rate. This compositional strategy incorporates a high nickel content into layered materials while eliminating cobalt, which is crucial for advancing the development of cost effective and high-performance lithium-ion battery technology.

Silver-Assisted Chemical Etching for the Fabrication of Porous Silicon N-Doped Nanohollow Carbon Spheres Composite Anodes to Enhance Electrochemical Performance.

Silicon (Si) shows great potential as an anode material for lithium-ion batteries. However, it experiences significant expansion in volume as it undergoes the charging and discharging cycles, presenting challenges for practical implementation. Nanostructured Si has emerged as a viable solution to address these challenges. However, it requires a complex preparation process and high costs. In order to explore the above problems, this study devised an innovative approach to create Si/C composite anodes: micron-porous silicon (p-Si) was synthesized at low cost at a lower silver ion concentration, and then porous silicon-coated carbon (p-Si@C) composites were prepared by compositing nanohollow carbon spheres with porous silicon, which had good electrochemical properties. The initial coulombic efficiency of the composite was 76.51%. After undergoing 250 cycles at a current density of 0.2 A·g-1, the composites exhibited a capacity of 1008.84 mAh·g-1. Even when subjected to a current density of 1 A·g-1, the composites sustained a discharge capacity of 485.93 mAh·g-1 even after completing 1000 cycles. The employment of micron-structured p-Si improves cycling stability, which is primarily due to the porous space it provides. This porous structure helps alleviate the mechanical stress caused by volume expansion and prevents Si particles from detaching from the electrodes. The increased surface area facilitates a longer pathway for lithium-ion transport, thereby encouraging a more even distribution of lithium ions and mitigating the localized expansion of Si particles during cycling. Additionally, when Si particles expand, the hollow carbon nanospheres are capable of absorbing the resulting stress, thus preventing the electrode from cracking. The as-prepared p-Si utilizing metal-assisted chemical etching holds promising prospects as an anode material for lithium-ion batteries.

Recycling and Reuse of Spent LIBs: Technological Advances and Future Directions.

Recovering valuable metals from spent lithium-ion batteries (LIBs), a kind of solid waste with high pollution and high-value potential, is very important. In recent years, the extraction of valuable metals from the cathodes of spent LIBs and cathode regeneration technology are still rapidly developing (such as flash Joule heating technology to regenerate cathodes). This review summarized the studies published in the recent ten years to catch the rapid pace of development in this field. The development, structure, and working principle of LIBs were firstly introduced. Subsequently, the recent developments in mechanisms and processes of pyrometallurgy and hydrometallurgy for extracting valuable metals and cathode regeneration were summarized. The commonly used processes, products, and efficiencies for the recycling of nickel-cobalt-manganese cathodes (NCM/LCO/LMO/NCA) and lithium iron phosphate (LFP) cathodes were analyzed and compared. Compared with pyrometallurgy and hydrometallurgy, the regeneration method was a method with a higher resource utilization rate, which has more industrial application prospects. Finally, this paper pointed out the shortcomings of the current research and put forward some suggestions for the recovery and reuse of spent lithium-ion battery cathodes in the future.

Materials recovery from NMC batteries with water as the sole solvent.

We report an environmentally benign recycling approach for large-capacity nickel manganese cobalt (NMC) batteries through the electrochemical concentration of lithium on the anode and subsequent recovery with only water. Cycling of the NMC pouch cells indicated the potential for maximum lithium recovery at a 5C charging rate. The anodes extracted from discharged and disassembled cells were submerged in deionized water, resulting in lithium dissolution and graphite recovery from the copper foils. A maximum of 13 mg of lithium salts per 100 mg of the anode, copper current collector, and separator was obtained from NMC pouch cell cycled at a 4C charging rate. The lithium salts extracted from batteries cycled at low C-rates were richer in lithium carbonate, while the salts from batteries cycled at high C-rates were richer in lithium oxides and peroxides, as determined by X-Ray photoelectron spectroscopy. The present method can be successfully used to recover all the pouch cell components: lithium, graphite, copper, and aluminum current collectors, separator, and the cathode active material.

Interfacial engineering in SnO2-embedded graphene anode materials for high performance lithium-ion batteries.

Tin dioxide is regarded as an alternative anode material rather than graphite due to its high theoretical specific capacity. Modification with carbon is a typical strategy to mitigate the volume expansion effect of SnO2 during the charge process. Strengthening the interface bonding is crucial for improving the electrochemical performance of SnO2/C composites. Here, SnO2-embedded reduced graphene oxide (rGO) composite with a low graphene content of approximately 5 wt.% was in situ synthesized via a cetyltrimethylammonium bromide (CTAB)-assisted hydrothermal method. The structural integrity of the SnO2/rGO composite is significantly improved by optimizing the Sn-O-C electronic structure with CTAB, resulting a reversible capacity of 598 mAh g-1 after 200 cycles at a current density of 1 A g-1. CTAB-assisted synthesis enhances the rate performance and cyclic stability of tin dioxide/graphene composites, and boosts their application as the anode materials for the next-generation lithium-ion batteries.

Boosting Conversion of the Si-O Bond by Introducing Fe2+ in Carbon-Coated SiOx for Superior Lithium Storage.

SiOx-based anodes are of great promise for lithium-ion batteries due to their low working potential and high specific capacity. However, several issues involving large volume expansion during the lithiation process, low intrinsic conductivity, and unsatisfactory initial Coulombic efficiency (ICE) hinder their practical application. Here, an Fe-SiOx@C composite with significantly improved lithium-storage performance was successfully synthesized by combining Fe2+ modification with a carbon coating strategy. The results of both experiments and density functional theory calculations confirm that the Fe2+ modification not only effectively achieves uniform carbon coating but also weakens the bonding energy of the Si-O bond and boosts reversible lithiation/delithiation reactions, resulting in great improvement in the electrical conductivity, ICE, and reversible specific capacity of the as-obtained Fe-SiOx@C. Together with the coated carbon, the in situ-generated conductive Fe-based intermediates also ensure the electrical contact of active components, relieve the volume expansion, and maintain the structural integrity of the electrode during cycling. And the Fe-SiOx@C (x ≈ 1.5) electrode can deliver a high-rate capacity of 354 mA h g-1 at 2.0 A g-1 and long-term cycling stability (552.4 mA h g-1 at 0.5 A g-1 even after 500 cycles). The findings here provide a facile modification strategy to improve the electrochemical lithium-storage performance of SiOx-based anodes.

In-situ Formation of a LiF-rich Interphase for Graphite Anode Operated at Low Temperatures.

Inorganic LiF is generally a desirable component in solid electrolyte interface (SEI) for graphite anode due to its electronic insulation, low Li+ diffusion barrier, high modulus and good chemical stability. Herein, fluorinated carbon (CFx) was incorporated into graphite material, which exhibited a high discharge potential prior to electrolyte decomposition and in-situ formed a crystalline LiF-based SEI with improved Li+ diffusion rate. The optimized graphite anode therefore demonstrated a fast-charging capability with 124 mAh g-1 at high rate of 8 C and a remarkable capacity retention of 83.8% at the low temperature of -30 oC compared to that at 25 oC. Furthermore, the optimized graphite|LiFePO4 full cell exhibited a significantly high discharge capacity of 109 mAh g-1 at -30 oC, corresponding to a notable 77.3% room-temperature capacity retention. These findings highlight a facile strategy to attain a LiF-rich SEI for high-performance lithium-ion batteries.

Structural Positive Electrodes Engineered for Multifunctionality.

Multifunctional structural batteries are of high and emerging interest in a wide variety of high-strength and lightweight applications. Structural batteries typically use pristine carbon fiber as the negative electrode, functionalized carbon fiber as the positive electrode, and a mechanically robust lithium-ion transporting electrolyte. However, electrochemical cycling of carbon fibre-based positive electrodes is still limited to tests in liquid electrolytes, which does not allow for to introduction of multifunctionality in real terms. To overcome these limitations, structural batteries with a structural battery electrolyte (SBE) are developed. This approach offers massless energy storage. The electrodes are manufactured using economically friendly, abundant, cheap, and non-toxic iron-based materials like olivine LiFePO4. Reduced graphene oxide, renowned for its high surface area and electrical conductivity, is incorporated to enhance the ion transport mechanism. Furthermore, a vacuum-infused solid-liquid electrolyte is cured to bolster the mechanical strength of the carbon fibers and provide a medium for lithium-ion migration. Electrophoretic deposition is selected as a green process to manufacture the structural positive electrodes with homogeneous mass loading. A specific capacity of 112 mAh g-1 can be reached at C/20, allowing the smooth transport of Li-ion in the presence of SBE. The modulus of positive electrodes exceeded 80 GPa. Structural battery-positive half-cells are demonstrated across various mass-loadings, enabling them to be tailored for a diverse array of applications in consumer technology, electric vehicles, and aerospace sectors.

A Review of Design Strategies in SiO/C Composite Anodes for Rechargeable Lithium-Ion Batteries.

Lithium-ion batteries (LIBs) are widely used in electric vehicles, portable electronic devices, clean energy storage, and other fields due to their long service life, high energy density, and low self-discharge rate, which also puts forward higher requirements for the performance of lithium-ion batteries. As an anode for lithium-ion batteries, SiO materials have garnered significant attention from researchers due to its high specific capacity (2400 mAh·g-1), abundance of raw materials, and simple preparation. However, its large volume change (~ 200%) and poor electrical conductivity hinder its large-scale commercial application. Researchers employ various methods to reduce the volume change of SiO during lithium intercalation and improve its structural stability during cycling. This work mainly reviews the chemical structure and lithium storage mechanism of SiO, as well as the latest research progress on the preparation methods of SiO/C anode materials, focusing on summarizing the following preparation strategies: chemical vapor deposition, mechanical ball milling, spray drying, and in-situ reduction/oxidation methods. The obtained SiO-based anode materials' structural characteristics and electrochemical properties are compared and summarized. Finally, this review discusses the advantages and disadvantages of the current preparation methods, the future research directions, and the development prospects of SiO-based anode materials.

A theoretical study of surface lithium effects on the [111] SiC nanowires as anode materials.

CONTEXT: Silicon carbide nanowires (SiCNWs) are considered a promising alternative material for application in lithium-ion batteries, with researchers striving to develop new electrode materials that exhibit high capacity and high charge/discharge rate performance. To gain a deeper understanding of the application of SiCNWs in semiconductor material science and energy supply fields, we investigated the effects of nanoscale and surface lithiation on the electrical and mechanical properties of SiCNWs grown along the [111] direction. First-principles calculation was used to study their geometries, electronic structures, and associated electrochemical properties. Herein, we considered SiCNWs with full hydrogen passivation, full lithium passivation, and mixed passivation at different sizes. The formation energy indicates that the stability of SiCNWs increases with the increasing diameter, and the surface-lithiated SiC nanowires (Li-SiCNWs) are found to be energetically stable. The mixed passivated SiCNWs exhibit the properties of indirect band gap with the increase of lithium atoms on the surface, while the fully lithium passivated nanowires exhibit metallic behavior. Charge analysis shows that a portion of the electrons on the lithium atoms are transferred to the surface atoms of the nanowires and electrons prefer to cluster more near the C atoms. Additionally, Li-SiCNWs still have good mechanical resistance during the lithiation process. The stable open-circuit voltage range and theoretical capacity of these SiCNWs indicate their suitability as anode materials. METHOD: In this study, Materials Studio 8.0 was used to construct the models of the SiCNWs. And all the density functional theory (DFT) calculations were performed by the Vienna ab initio Simulation Package (VASP). The self-consistent field calculations are performed over a Monkhorst-Pack net of 1 × 1 × 6 k-points. The energy convergence criteria for the self-consistent field calculation were set to 10-5 eV/atom with a cutoff energy of 400 eV.

Comparative impact of surface and bulk fluoride anion doping on the electrochemical performance of co-free Li-rich Mn-based layered cathodes.

Li-rich Mn-based (LMR) layered oxides are considered promising cathode materials for high energy-density Li-ion batteries. Nevertheless, challenges such as irreversible oxygen loss at the surface during the initial charge, alteration of the bulk structure, and poor rate performance impede their path to commercialisation. Most modification methods focus on specific layers, making the overall impact of modifications at various depths on the properties of materials unclear. This research presents an approach by using doping to adjust both surface and bulk properties; the materials with surface and bulk fluoride anion doping are synthesised to explore the connection between doping depth, structural and electrochemical stability. The surface-doped material significantly improves the initial Coulombic efficiency (ICE) from 77.85% to 85.12% and limits phase transitions, yet it does not enhance rate performance. Conversely, doping in bulk stands out by improving both rate performance and cyclic stability: it increases the specific discharge capacity by around 60 mAh g-1 and enhances capacity retention from 57.69% to 82.26% after 300 cycles at 5C. These results highlight a notable dependence of material properties on depth, providing essential insights into the mechanisms of surface and bulk modifications.

Covalent Organic Framework-Coated Polyimide Ion-Track-Etched Separator with High Thermal Stability for Developing Lithium-Ion Batteries with Long Lifespans.

Separators play a crucial role in inhibiting thermal runaway in lithium-ion batteries (LIBs). In this study, the doctor blade coating method and heavy-ion track etching technology were used to prepare a polyimide-based covalent organic framework (PI_COF) separator with excellent thermal stability and a long cycle life. Specifically, COF300 was simply coated on the surface of a polyimide-based track-etched membrane (PI_TEM) with straight through holes, which provided a rigid framework and high-temperature stability at 300 °C. These features were conducive to inhibiting thermal runaway, while porous COF300 with large holes increased the wettability of the electrolyte, facilitating lithium-ion migration and suppression of lithium dendrite growth; consequently, LIBs with an excellent cycling performance and a high rate capacity were obtained. The cell with the PI_COF separator delivered a high capacity of 90.0 mA h g-1 after 1000 cycles. The PI_COF separator with high thermal stability exhibited a long cycle life in LIBs. These features are beneficial for improving the safety characteristics of LIBs as well as for accelerating the practical application process of the PI_COF separator.

Exploring Phenolphthalein Polyarylethers as High-Performance Alternative Binders for High-Voltage Cathodes in Lithium-Ion Batteries.

Polyvinylidene fluoride (PVDF) has unique electrochemical oxidation resistance and is the only binder for high-voltage cathode materials in the battery industry for a long time. However, PVDF still has some drawbacks, such as environmental limitations on fluorine, strict requirements for environmental humidity, weak adhesion, and poor lithium ion conductivity. Herein, the long-standing issues associated with high-voltage lithium cobalt oxide (LiCoO2; LCO) are successfully addressed by incorporating phenolphthalein polyetherketone (PEK-C) and phenolphthalein polyethersulfone (PES-C) as binder materials. These binders have unexpected electrochemical oxidation resistance and robustness adhesion, ensure uniform coverage on the surface of LCO, and establish an effective and fast ion-conductive CEI/binder composite layer. By leveraging these favorable characteristics, electrodes based on polyarylether binders demonstrate significantly better cycling and rate performance than their counterparts using traditional PVDF binders. The fast ion-conductive CEI/binder composite layer effectively mitigates adverse reactions at the cathode-electrolyte interface. As anticipated, batteries utilizing phenolphthalein polyarylether binders exhibit capacity retention rates of 88.92% and 80.4% after 200 and 500 cycles at 4.5 and 4.6 V, respectively. The application of binders, such as polyarylether binders, offers a straightforward and inspiring approach for designing high-energy-density battery materials.

Extended Plateau Capacity of Hard Carbon Anode for High Energy Lithium-Ion Batteries.

Hard carbon materials have shown promising potential for sodium-ion storage due to accommodating larger sodium ions. However, as for lithium-ion storage, the challenge lies in tuning the high lithiation plateau capacities, which impacts the overall energy density. Here, hard carbon microspheres (HCM) are prepared by tailoring the cross-linked polysaccharide, establishing a comprehensive methodology to obtain high-performance lithium-ion batteries (LIBs) with long plateau capacities. The "adsorption-intercalation mechanism" for lithium storage is revealed combining in situ Raman characterization and ex situ nuclear magnetic resonance spectroscopy. The optimized HCM possesses reduced defect content, enriched graphitic microcrystalline, and low specific surface area, which is beneficial for fast lithium storage. Therefore, HCM demonstrates a high reversible capacity of 537 mAh g-1 with a significant low-voltage plateau capacity ratio of 55%, high initial Coulombic efficiency, and outstanding rate performance (152 mAh g-1 at 10 A g-1). Moreover, the full cell (HCM||LiCoO2) delivers outstanding fast-charging capability (4 min charge to 80% at 10 C) and impressive energy density of 393 Wh kg-1. Additionally, 80% reversible capacity can be delivered under -40 °C with competitive cycling stability. This work provides in-depth insights into the rational design of hard carbon structures with extended low-voltage plateau capacity for high energy LIBs.

Molybdenum-Doped Cobalt-Free Cathode Realizing the Electrochemical Stability by Enhanced Covalent Bonding.

The doping strategy effectively enhances the capacity and cycling stability of cobalt-free nickel-rich cathodes. Understanding the intrinsic contributions of dopants is of great importance to optimize the performances of cathodes. This study investigates the correlation between the structure modification and their performances of Mo-doped LiNi0.8Mn0.2O2 (NM82) cathode. The role of doped Mo's valence state has been proved functional in both lattice structural modification and electronic state adjustment. Although the high-valence of Mo at the cathode surface inevitably reduces Ni valence for electronic neutrality and thus causes ion mixing, the original Mo valence will influence its diffusion depth. Structural analyses reveal Mo doping leads to a mixed layer on the surface, where high-valence Mo forms a slender cation mixing layer, enhancing structural stability and Li-ion transport. In addition, it is found that the high-valence dopant of Mo6+ ions partially occupies the unfilled 4d orbitals, which may strengthen the Mo─O bond through increased covalency and therefore reduce the oxygen mobility. This results in an impressive capacity retention (90.0% after 200 cycles) for Mo-NM82 cathodes with a high Mo valence state. These findings underscore the valence effect of doping on layered oxide cathode performance, offering guidance for next-generation cathode development.

Carbon-Based 3D Architectures as Anodes for Lithium-Ion Battery Systems.

Graphite, with its exceptional cyclic performance, continues to dominate as the preferred anode material for lithium-ion batteries. However as high-energy application gains momentum, there is growing demand for higher capacities that alloying/de alloying and conversion type anode materials can offer. Despite their potential, these materials are plagued by challenges such as volumetric fluctuations, low conductivities, and poor cyclic stability. Carbon nanostructures, on the other hand, show tremendous promise with their low volume expansion, high ion diffusion rates, and excellent conductivity. Nevertheless, their limited areal and volumetric densities restrict their widespread utilization. To address these limitations, various strategies such as doping, composite formation, and structural modification have been proposed. This article provides a succinct overview of carbon nanomaterials and their electrochemical performance as 3D carbon-based anodes, along with a comprehensive analysis of the strategies employed to overcome associated challenges while evaluating their potential prospects in the field.