Work

Electrochemistry‐Driven Complete Reconstruction of Spent Lithium–Ion Battery Cathodes for Matter Recycling

Year: 2025

Type: article

Abstract: The rapid expansion of lithium–ion batteries (LIBs) applications has created urgent recycling challenges. To tackle these issues, this study proposes a novel electrochemistry‐driven complete reconstruction (EDCR) strategy for effective recycling of cathode materials. The well‐designed electrochemical cell is based on a used aluminum foil anode and spent cathodes in a tamed chloroaluminate molten salt electrolyte. During the discharge process, the spent cathodes undergo a reduction reaction, converting high‐valence transition metals into their elemental forms. After deep discharge, the spent LiCoO 2 cathode completely decomposes into Co, LiCl, and Al 2 O 3 . Subsequent treatment involving washing and calcination produces a pure LiCl solution and a mixed solid of Co 3 O 4 and Al 2 O 3 , which can be used to synthesize new cathode materials directly. Experimental results demonstrate the versatility of this method, achieving high recovery rates for LiCoO 2 , ternary cathodes (including NCM811 and NCA), as well as lithium–iron phosphate (LiFePO 4 ). When compared to traditional pyrometallurgical and hydrometallurgical methods, the EDCR strategy notably lowers energy consumption by 23% and reduces greenhouse gas emissions, all while ensuring a streamlined workflow, reduced operational costs, and a competitive profit margin of $1.96 per kilogram of batteries processed. This work paves the way for a sustainable closed‐loop LIB resource recovery.

Source: Batteries & Supercaps

DOI: 10.1002/batt.202500113