High-energy, long-life Ni-rich cathode materials with columnar structures for all-solid-state batteries
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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.
An Integrative lifecycle design approach based on carbon intensity for renewable-battery-consumer energy systems
Driven by sustainable development goals and carbon neutrality worldwide, demands for both renewable energy and storage systems are constantly increasing. However, the lack of an appropriate approach without considering renewable intermittence and demand stochasticity will lead to capacity oversizing or undersizing. In this study, an optimal design approach is proposed for integrated photovoltaic-battery-consumer energy systems in the form of a m2-kWp-kWh relationship in both centralized and distributed formats. Superiorities of the proposed matching degree approach are compared with the traditional uniformity approach, in photovoltaic capacity, battery capacity, net present value and lifecycle carbon intensity. Results showed that the proposed method is superior to the traditional approach with higher net present value and lower carbon intensity. Furthermore, the proposed method can be scaled and applied to guide the design of photovoltaic-battery-consumer energy systems in different climate zones, promoting sustainable development and carbon neutrality globally.
Flash Joule heating for synthesis, upcycling and remediation
Electric heating methods are being developed and used to electrify industrial applications and lower their carbon emissions. Direct Joule resistive heating is an energy-efficient electric heating technique that has been widely tested at the bench scale and could replace some energy-intensive and carbon-intensive processes. In this Review, we discuss the use of flash Joule heating (FJH) in processes that are traditionally energy-intensive or carbon-intensive. FJH uses pulse current discharge to rapidly heat materials directly to a desired temperature; it has high-temperature capabilities (>3,000 °C), fast heating and cooling rates (>102 °C s−1), short duration (milliseconds to seconds) and high energy efficiency (~100%). Carbon materials and metastable inorganic materials can be synthesized using FJH from virgin materials and waste feedstocks. FJH is also applied in resource recovery (such as from e-waste) and waste upcycling. An emerging application is in environmental remediation, where FJH can be used to rapidly degrade perfluoroalkyl and polyfluoroalkyl substances and to remove or immobilize heavy metals in soil and solid wastes. Life-cycle and technoeconomic analyses suggest that FJH can reduce energy consumption and carbon emissions and be cost-efficient compared with existing methods. Bringing FJH to industrially relevant scales requires further equipment and engineering development.
Decarbonizing urban residential communities with green hydrogen systems
Community green hydrogen systems, typically consisting of rooftop photovoltaic panels paired with hybrid hydrogen-battery storage, offer urban environments with improved access to clean, on-site energy. However, economically viable pathways for deploying hydrogen storage within urban communities remain unclear. Here we develop a bottom-up energy model linking climate, human behavior and community characteristics to assess the impacts of pathways for deploying community green hydrogen systems in North America from 2030 to 2050. We show that for the same community conditions, the cost difference between the best and worst pathways can be as high as 60%. In particular, the household centralized option emerges as the preferred pathway for most communities. Furthermore, enhancing energy storage demands within these deployment pathways can reduce system design costs up to fourfold. To achieve cost-effective urban decarbonization, the study underscores the critical role of selecting the right deployment pathway and prioritizing the integration of increased energy storage in pathway designs.
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.
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