Self-looped electrochemical recycling of lithium-ion battery cathode materials to manufacturing feedstocks
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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.
A combination of measures limits demand for critical materials in Sweden’s electric car transition
Electrification of passenger cars will result in an increased demand for critical raw materials. Here we estimate the quantities of nickel, manganese, cobalt, lithium, and graphite that could be required for a transition to electric cars in Sweden and how different measures can limit material demand. We find notable reduction potentials for shorter battery range—enabled by improved charging infrastructure, increased vehicle energy efficiency, and reduced travel demand compared to a reference scenario. The reduction potentials for downsizing and more lightweight cars, and car sharing are more modest. The combined impact of these measures would be 50–75% reduction in cumulative demand and 72–87% reduction in in-use stock in 2050, depending on the material and battery chemistry pathway. Generally, the reduction potentials are larger than the potential contributions from recycling, suggesting that these complementary measures may be more effective in reducing material demand.
ToF-SIMS sputter depth profiling of interphases and coatings on lithium metal surfaces
Lithium metal as a negative electrode material offers ten times the specific capacity of graphitic electrodes, but its rechargeable operation poses challenges like excessive and continuous interphase formation, high surface area lithium deposits and safety issues. Improving the lithium | electrolyte interface and interphase requires powerful surface analysis techniques, such as ToF-SIMS sputter depth profiling.This study investigates lithium metal sections with an SEI layer by ToF-SIMS using different sputter ions. An optimal sputter ion is chosen based on the measured ToF-SIMS sputter depth profiles and SEM analysis of the surface damage. Further, this method is adapted to lithium metal foil with an intermetallic coating. ToF-SIMS sputter depth profiles in both polarities provide comprehensive insights into the coating structure. Both investigations highlight the value of ToF-SIMS sputter depth profiling in lithium metal battery research and offer guidance for future studies.
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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