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

One-Step Molten-Salt-Assisted Approach for Direct Preparation and Regeneration of LiNi0.6Co0.2Mn0.2O2 Cathode

Single-crystal lithium-nickel-manganese-cobalt-oxide (SC-NMC) is attracting increasing attention due to its excellent structural stability. However, its practical production faces challenges associated with complex precursor preparation processes and severe lithium-nickel cation mixing at high temperatures, which restricts its widespread application. Here, a molten-salt-assisted method is proposed using low-melting-point carbonates. This method obviates the necessity for precursor processes and simplified the synthetic procedure for SC-NMC down to a single isothermal sintering step. Multiple characterizations indicate that the acquired SC-LiNi0.6Mn0.2Co0.2O2 (SC-622) exhibits favorable structural capability against intra-granular fracture and suppressive Li+/Ni2+ cation mixing. Consequently, the SC-622 exhibits superior electrochemical performance with a high initial specific capacity (174 mAh g-1 at 0.1 C, 3.0-4.3 V) and excellent capacity retention (87.5% after 300 cycles at 1C). Moreover, this molten-salt-assisted method exhibits its effectiveness in directly regenerating SC-622 from spent NMC materials. The recovered material delivered a capacity of 125.4 mAh g-1 and retained 99.4% of the initial capacity after 250 cycles at 1 C. This work highlights the importance of understanding the process-structure-property relationships and can broadly guide the synthesis of other SC Ni-rich cathode materials.

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.

Fast Li Replenishment Channels-Assisted Recycling of Degraded Layered Cathodes with Enhanced Cycling Performance and Thermal Stability

The direct recycling of cathode materials in lithium-ion batteries is important for environmental protection and resource conservation. The key regeneration processes are composition replenishment and atom rearrangement, both of which depend on the migration and diffusion of atoms. However, for the direct recycling of degraded LiNi0.5 Co0.2 Mn0.3 O2 (D-NCM523) cathode, the irreversible phase transitions that accumulate during the long-term cycles block the Li diffusion channels with a high diffusion energy barrier, making it difficult to fully repair the layered structure and resulting in rapid capacity decay. To address the challenge, fast Li replenishment channels are rebuilt to regulate the surface phase and effectively assist the regeneration process with a reduced energy barrier. This method reduces the amount of Li supplement by >75% and shortens the sintering time (only 2 h) to fully regenerate D-NCM523, compared to general direct recycling methods. The regenerated NCM523 (LCMB-NCM523) exhibits a satisfactory repaired specific capacity of 160 mAh g-1 and excellent cycling stability, retaining 78% of its capacity after 300 cycles. In addition, LCMB-NCM523 is recycled with improved thermal decomposition peak temperature and enables 200 cycles even at 60 °C, greatly improving safety. This work proposes a promising way for the large-scale direct regeneration of layered cathodes.

Self-Reconstruction of Highly Degraded LiNi0.8 Co0.1 Mn0.1 O2 toward Stable Single-Crystalline Cathode

The ever-growing demand for resources sustainability has promoted the recycle of spent lithium-ion batteries to a strategic position. Direct recycle outperforms either hydrometallurgical or pyrometallurgical approaches due to the high added value and facile treatment processes. However, the traditional direct recycling technologies are only applicable for Ni-poor/middle cathodes. Herein, spent Ni-rich LiNi0.8 Co0.1 Mn0.1 O2 (S-NCM) to performance-enhanced single-crystalline cathode materials is directly recycled using a simple but effective LiOH-NaCl molten salt. The evolution process of the Li-supplement and grain-recrystallization during regeneration is systematically investigated, and the successful recovery of the highly degraded microstructure is comprehensively proven, including significant elimination of Ni2+ and O vacancies. Beneficial from the favorable reconstructed single-crystalline particles, the regenerated NCM (R-NCM) represents remarkably enhanced structural stability, electrochemical activity, O2 and cracks suppression during charge/discharge, thus achieving the excellent performances in long-term cycling and high-rate tests. As a result, R-NCM maintains the 86.5% reversible capacity at 1 C after 200 cycles. Instructively, the present molten salt can be successfully applied for recycling spent NCMs with various Li and Ni compositions (e.g., LiNi0.5 Co0.2 Mn0.3 O2 ).

New Insights into the All-Dry Synthesis of NMC622 Cathodes Using a Single-Phase Rock Salt Oxide Precursor

In this study, new insights into the all-dry synthesis of the LiNi0.6Mn0.2Co0.2O2 (NMC622) cathode using a single-phase rock-salt (RS) oxide precursor are provided. It was found that use of a larger amount of excess Li content not only can enhance the electrochemical performance of NMC made from the RS-precursor but also increase the degree of homogeneity of the NMC cathode material. In situ XRD analysis showed that lithiation of the RS-precursor (i.e., formation of the O3-phase) starts at a higher synthesis temperature (∼450 °C) than that is required when using a hydroxide precursor (HP) and lithium carbonate (∼350 °C). Consequently, Li2CO3 was consumed by the reaction with the HP at low temperatures before the temperature reached the Li2CO3 melting point. In contrast, the reduced lithiation kinetics of the RS-precursor results in the presence of liquid Li2CO3 during the synthesis, which rapidly increases the rates of precursor lithiation and increases the NMC primary particle size.

Direct Regenerating Cathode Materials from Spent Lithium-Ion Batteries

Recycling cathode materials from spent lithium-ion batteries (LIBs) is critical to a sustainable society as it will relief valuable but scarce recourse crises and reduce environment burdens simultaneously. Different from conventional hydrometallurgical and pyrometallurgical recycling methods, direct regeneration relies on non-destructive cathode-to-cathode mode, and therefore, more time and energy-saving along with an increased economic return and reduced CO2 footprint. This review retrospects the history of direct regeneration and discusses state-of-the-art development. The reported methods, including high-temperature solid-state, hydrothermal/ionothermal, molten salt thermochemistry, and electrochemical method, are comparatively introduced, targeting at illustrating their underlying regeneration mechanism and applicability. Further, representative repairing and upcycling studies on wide-applied cathodes, including LiCoO2 (LCO), ternary oxides, LiFePO4 (LFP), and LiMn2 O4 (LMO), are presented, with an emphasis on milestone cases. Despite these achievements, there remain several critical issues that shall be addressed before the commercialization of the mentioned direct regeneration methods.

Toward Sustainable All Solid-State Li-Metal Batteries: Perspectives on Battery Technology and Recycling Processes

Lithium (Li)-based batteries are gradually evolving from the liquid to the solid state in terms of safety and energy density, where all solid-state Li-metal batteries (ASSLMBs) are considered the most promising candidates. This is demonstrated by the Bluecar electric vehicle produced by the Bolloré Group, which is utilized in car-sharing services in several cities worldwide. Despite impressive progress in the development of ASSLMBs, their avenues for recycling them remain underexplored, and combined with the current explosion of spent Li-ion batteries, they should attract widespread interest from academia and industry. Here, the potential challenges of recycling ASSLMBs as compared to Li-ion batteries are analyzed and the current progress and prospects for recycling ASSLMBs are summarized and analyzed. Drawing on the lessons learned from Li-ion battery recycling, it is important to design sustainable recycling technologies before ASSLMBs gain widespread market adoption. A battery-recycling-oriented design is also highlighted for ASSLMBs to promote the recycling rate and maximize profitability. Finally, future research directions, challenges, and prospects are outlined to provide strategies for achieving sustainable development of ASSLMBs.

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.

Topotactic Transformation of Surface Structure Enabling Direct Regeneration of Spent Lithium-Ion Battery Cathodes

Recycling spent lithium-ion batteries (LIBs) has become an urgent task to address the issues of resource shortage and potential environmental pollution. However, direct recycling of the spent LiNi_0.5Co_0.2Mn_0.3O₂ (NCM523) cathode is challenging because the strong electrostatic repulsion from a transition metal octahedron in the lithium layer provided by the rock salt/spinel phase that is formed on the surface of the cycled cathode severely disrupts Li⁺ transport, which restrains lithium replenishment during regeneration, resulting in the regenerated cathode with inferior capacity and cycling performance. Here, we propose the topotactic transformation of the stable rock salt/spinel phase into Ni_0.5Co_0.2Mn_0.3(OH)₂ and then back to the NCM523 cathode. As a result, a topotactic relithiation reaction with low migration barriers occurs with facile Li⁺ transport in a channel (from one octahedral site to another, passing through a tetrahedral intermediate) with weakened electrostatic repulsion, which greatly improves lithium replenishment during regeneration. In addition, the proposed method can be extended to repair spent NCM523 black mass, spent LiNi_0.6Co_0.2Mn_0.2O₂, and spent LiCoO₂ cathodes, whose electrochemical performance after regeneration is comparable to that of the commercial pristine cathodes. This work demonstrates a fast topotactic relithiation process during regeneration by modifying Li⁺ transport channels, providing a unique perspective on the regeneration of spent LIB cathodes.

Aluminum Impurity from Current Collectors Reactivates Degraded NCM Cathode Materials toward Superior Electrochemical Performance

The huge amount of degraded NCM (LiNi_0.5Co_0.2Mn_0.3O₂) cathode materials from spent lithium-ion batteries is arising as a serious environmental issue as well as a severe waste of metal resources, and therefore, direct recycling of them toward usable electrode materials again is environmentally and economically more attractive in contrast to present metallurgical treatments. In this work, we design a robust two-step method for direct recycling of degraded NCM materials, which uses the aluminum impurity from the attached current collector to supplement the transition metal vacancies for simultaneous elemental compensation and structural restoration. This single-element compensation strategy leads to the regeneration of high-quality NCM material with depressed cation disordering and stabilized layered structure. Moreover, the regenerated NCM material with controllable Al doping delivered an outstanding electrochemical performance; specifically, the capacity (158.6 mAh g^-1), rate capability (91.6 mAh g^-1 at 5 C), and cycling stability (89.6% capacity retention after 200 cycles) of the regenerated NCM material are even comparable with those of fresh materials. The as-established regeneration protocol has its chance in simplifying the industrial recycling process of degraded NCM materials.

Repurposing of spent lithium-ion battery separator as a green reductant for efficiently refining the cathode metals

Developing green and high-efficient pyrometallurgy processes to recycle precious metals from spent lithium-ion batteries (LIBs) is of great importance for resource sustainability and environmental protection. Herein, a novel reduction roasting approach relying on spent LIB separator to refine the spent cathode is proposed. The efficiency of repurposing separator as a reductant for roasting the spent LiCoO₂ cathode and the underlying mechanisms were investigated. After the separator-mediated roasting at 500 °C for 2 h, Li⁺ leaching efficiency of the cathode reached 93.2 %, >2.6 times higher than those after roasting without reductant (25.2 %) or with benchmark reductant graphite (26.1 %). Under the separator-added roasting condition, the cathode was converted to the desired products, CoO and Li₂CO₃. Based on the analysis of in-situ reaction using thermogravimetric/differential scanning calorimetry and pyrolysis gas species identification, the separator-mediated reduction roasting of cathode was composed of two stages, i.e., reducing gas generation due to separator pyrolysis, followed by the reducing gas mediated LiCoO₂ reduction. During the process, the generated C₂H₄ and CO dominated the reduction. The use of co-existing separator to recover precious metals from spent LIBs is an effective and sustainable strategy to maximize the utilization of spent LIBs.

Progress, Key Issues, and Future Prospects for Li-Ion Battery Recycling

The overuse and exploitation of fossil fuels has triggered the energy crisis and caused tremendous issues for the society. Lithium-ion batteries (LIBs), as one of the most important renewable energy storage technologies, have experienced booming progress, especially with the drastic growth of electric vehicles. To avoid massive mineral mining and the opening of new mines, battery recycling to extract valuable species from spent LIBs is essential for the development of renewable energy. Therefore, LIBs recycling needs to be widely promoted/applied and the advanced recycling technology with low energy consumption, low emission, and green reagents needs to be highlighted. In this review, the necessity for battery recycling is first discussed from several different aspects. Second, the various LIBs recycling technologies that are currently used, such as pyrometallurgical and hydrometallurgical methods, are summarized and evaluated. Then, based on the challenges of the above recycling methods, the authors look further forward to some of the cutting-edge recycling technologies, such as direct repair and regeneration. In addition, the authors also discuss the prospects of selected recycling strategies for next-generation LIBs such as solid-state Li-metal batteries. Finally, overall conclusions and future perspectives for the sustainability of energy storage devices are presented in the last chapter.

A Minireview on the Regeneration of NCM Cathode Material Directly from Spent Lithium-Ion Batteries with Different Cathode Chemistries

Research on the regeneration of cathode materials of spent lithium-ion batteries for resource reclamation and environmental protection is attracting more and more attention today. However, the majority of studies on recycling lithium-ion batteries (LIBs) placed the emphasis only on recovering target metals, such as Co, Ni, and Li, from the cathode materials, or how to recycle spent LIBs by conventional means. Effective reclamation strategies (e.g., pyrometallurgical technologies, hydrometallurgy techniques, and biological strategies) have been used in research on recycling used LIBs. Nevertheless, none of the existing reviews of regenerating cathode materials from waste LIBs elucidated the strategies to regenerate lithium nickel manganese cobalt oxide (NCM or LiNixCoyMnzO2) cathode materials directly from spent LIBs containing other than NCM cathodes but, at the same time, frequently used commercial cathode materials such as LiCoO2 (LCO), LiFePO4 (LFP), LiMn2O4 (LMO), etc. or from spent mixed cathode materials. This review showcases the strategies and techniques for regenerating LiNixCoyMnzO2 cathode active materials directly from some commonly used and different types of mixed-cathode materials. The article summarizes the various technologies and processes of regenerating LiNixCoyMnzO2 cathode active materials directly from some individual cathode materials and the mixed-cathode scraps of spent LIBs without their preliminary separation. In the meantime, the economic benefits and diverse synthetic routes of regenerating LiNixCoyMnzO2 cathode materials reported in the literature are analyzed systematically. This minireview can lay guidance and a theoretical basis for restoring LiNixCoyMnzO2 cathode materials.

Surface Growth and Intergranular Separation of Polycrystalline Particles for Regeneration of Stable Single-Crystal Cathode Materials

The direct regeneration technology has been developed because of its short-range, high efficiency, and green characteristics. However, the existing direct regeneration method is hardly applied in collaborative reconstruction of the damaged crystal and particle of spent polycrystalline layered materials. The single-crystal regeneration with restructuring the morphology and crystal structure was herein achieved for the first time by low-temperature lithium supplementation followed with high-temperature molten salt conversion, which could effectively solve the structural defects of spent polycrystalline layered materials. We found that the realization of single-crystal regeneration with the molten salt process is attributable to that the original crystal growth of primary particles in the polycrystal transfer to the subsequent division along the grain boundary. At the test conditions of 25 °C and 2.8-4.3 V, the capacity retention capacity of the regenerated single-crystal materials reach 83.3% after 200 cycles at 1 C, which is much higher than 20.0% for conventional direct lithiation regeneration and 61.6% for low-temperature molten salt regeneration. Interestingly, the regenerated single-crystal NCM622 in the graphite full-cell test displays a capacity retention rate of 85.24% after 800 cycles at a rate of 1 C at 2.5-4.35 V. This work opens up a new way for the direct regeneration of spent polycrystalline layered cathode materials.