A kosmotropic solution to cathode manufacturing
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The evolution of lithium-ion battery recycling
Demand for lithium-ion batteries (LIBs) is increasing owing to the expanding use of electrical vehicles and stationary energy storage. Efficient and closed-loop battery recycling strategies are therefore needed, which will require recovering materials from spent LIBs and reintegrating them into new batteries. In this Review, we outline the current state of LIB recycling, evaluating industrial and developing technologies. Among industrial technologies, pyrometallurgy can be broadly applied to diverse electrode materials but requires operating temperatures of over 1,000 °C and therefore has high energy consumption. Hydrometallurgy can be performed at temperatures below 200 °C and has material recovery rates of up to 93% for lithium, nickel and cobalt, but it produces large amounts of wastewater. Developing technologies such as direct recycling and upcycling aim to increase the efficiency of LIB recycling and rely on improved pretreatment processes with automated disassembly and cleaner mechanical separation. Additionally, the range of materials recovered from spent LIBs is expanding from the cathode materials recycled with established methods to include anode materials, electrolytes, binders, separators and current collectors. Achieving an efficient recycling ecosystem will require collaboration between recyclers, battery manufacturers and electric vehicle manufacturers to aid the design and automation of battery disassembly lines.
Advanced electrode processing for lithium-ion battery manufacturing
Lithium-ion batteries (LIBs) need to be manufactured at speed and scale for their use in electric vehicles and devices. However, LIB electrode manufacturing via conventional wet slurry processing is energy-intensive and costly, challenging the goal to achieve sustainable, affordable and facile manufacturing of high-performance LIBs. In this Review, we discuss advanced electrode processing routes (dry processing, radiation curing processing, advanced wet processing and 3D-printing processing) that could reduce energy usage and material waste. Maxwell-type dry processing is a scalable alternative to conventional processing and has relatively low manufacturing cost and energy consumption. Radiation curing processing could enable high-throughput manufacturing, but binder selection is limited to certain radiation curable chemistries. 3D-printing processing can produce electrodes with diverse architectures and improved rate performance, but scalability is yet to be demonstrated. 3D-printing processing is good for special applications where throughput and cost can be compromised for performance.
3D printing of micro-nano devices and their applications
In recent years, the utilization of 3D printing technology in micro and nano device manufacturing has garnered significant attention. Advancements in 3D printing have enabled achieving sub-micron level precision. Unlike conventional micro-machining techniques, 3D printing offers versatility in material selection, such as polymers. 3D printing technology has been gradually applied to the general field of microelectronic devices such as sensors, actuators and flexible electronics due to its adaptability and efficacy in microgeometric design and manufacturing processes. Furthermore, 3D printing technology has also been instrumental in the fabrication of microfluidic devices, both through direct and indirect processes. This paper provides an overview of the evolving landscape of 3D printing technology, delineating the essential materials and processes involved in fabricating microelectronic and microfluidic devices in recent times. Additionally, it synthesizes the diverse applications of these technologies across different domains.
Mechanisms of electrochemical hydrogenation of aromatic compound mixtures over a bimetallic PtRu catalyst
Efficient electrochemical hydrogenation (ECH) of organic compounds is essential for sustainability, promoting chemical feedstock circularity and synthetic fuel production. This study investigates the ECH of benzoic acid, phenol, guaiacol, and their mixtures, key components in upgradeable oils, using a carbon-supported PtRu catalyst under varying initial concentrations, temperatures, and current densities. Phenol achieved the highest conversion (83.17%) with a 60% Faradaic efficiency (FE). In mixtures, benzoic acid + phenol yielded the best performance (64.19% conversion, 74% FE), indicating a synergistic effect. Notably, BA consistently exhibited 100% selectivity for cyclohexane carboxylic acid (CCA) across all conditions. Density functional theory (DFT) calculations revealed that parallel adsorption of BA on the cathode (−1.12 eV) is more stable than perpendicular positioning (-0.58 eV), explaining the high selectivity for CCA. These findings provide a foundation for future developments in ECH of real pyrolysis oil.
Direct observation of Mn-ion dissolution from LiMn2O4 lithium battery cathode to electrolyte
The degradation of lithium-ion batteries has become a concerning issue. One problem is metal ion dissolution from the cathode material, such as Mn2+ dissolution from spinel-type LiMn2O4 (LMO). However, direct observation of the dissolution process has yet to be reported. Here, we establish in-situ 1H nuclear magnetic resonance imaging (MRI) measurement as an efficient technique to observe Mn2+ dissolution from a model lithium battery with LMO as the cathode. We observe an increase in the MRI signal intensity near the cathode, confirming the dissolution of Mn2+ from the cathode to the electrolyte. Moreover, we show that Mn2+ dissolution from LMO can be suppressed using an appropriate choice of electrolytes. We believe the method developed here can answer the long-time unanswered question of when, where, and how the metal ion dissolution occurs in the lithium-ion battery electrode and can be extended to other electrochemical systems.
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