The lithium ion (Li-ion) battery industry has been growing exponentially since its initial inception in the late 20th century. As battery materials evolve, the applications for Li-ion batteries have become even more diverse. To date, the main source of Li-ion battery use varies from consumer portable electronics to electric/hybrid electric vehicles. However, even with the continued rise of Liion battery development and commercialization, the recycling industry is lagging; approximately 95% of Li-ion batteries are landfilled instead of recycled upon reaching end of life. Industrialized recycling processes are limited and only capable of recovering secondary raw materials, not suitable for direct reuse in new batteries. Most technologies are also reliant on high concentrations of cobalt to be profitable, and intense battery sortation is necessary prior to processing. For this reason, it is critical that a new recycling process be commercialized that is capable of recovering more valuable materials at a higher efficiency. A new technology has been developed by the researchers at Worcester Polytechnic Institute which is capable of recovering LiNi x Mn y Co z O 2 cathode material from a hydrometallurgical process, making the recycling system as a whole more economically viable. By implementing a flexible recycling system that is closed-loop, recycling of Li-ion batteries will become more prevalent saving millions of pounds of batteries from entering the waste stream each year.
The lithium-ion battery (LIB) recycling market is becoming increasingly important because of the widespread use of LIBs in every aspect of our lives. Mobile devices and electric cars represent the largest application areas for LIBs. Vigorous innovation in these sectors is spurring continuous deployment of LIB powered devices, and consequently more and more LIBs will become waste as they approach end of life. Considering the significant economic and environmental impacts, recycling is not only necessary, but also urgent. The WPI group has successfully developed a closed-loop recycling process, and has previously demonstrated it on a relatively small scale 1 kg spent batteries per experiment. Here, we show that the closed-loop recycling process can be successfully scaled up to 30 kg of spent LIBs from electric vehicle recycling streams, and the recovered cathode powder shows similar (or better) performance to equivalent commercial powder when evaluated in both coin cells and single layer pouch cells. All of these results demonstrate the closed-loop recycling process has great adaptability and can be further developed into industrial scale.
Branched Pd nanodendrites have been synthesized by a very simple method, which have displayed substantially enhanced oxygen reduction reaction (ORR) activity compared with that of commercial Pd/C catalysts. The Pd nanodendrites show 4.8 times more activity on the basis of an equivalent noble metal mass for the ORR than the commercial Pd/C catalysts. Moreover, the Pd nanodendrite catalysts also exhibit superior ethanol oxidation reaction (EOR) activity, making them excellent candidates as high performance multifunctional catalysts for both ORR and EOR.
For environmental and sustainability reasons, spent Li-ion batteries must be recovered and recycled so that the full promise of an electrified future is realized. Li-ion battery recycling streams pose a serious challenge to all existing recycling technologies because of their unknown and diverse chemistry. In the work described in this paper, four representative recycling streams were used to demonstrate the flexibility of the recycling process developed at Worcester Polytechnic Institute (WPI) to accommodate a variable feed and to generate consistent quality cathode material, LiNi1/3Mn1/3Co1/3O2 (NMC111). Ni1/3Mn1/3CO1/3(OH)2 precursors derived from four recycling streams were produced by a hydroxide coprecipitation method in a continuous stirred tank reactor. It took 2 days for the coprecipitation reaction to reach steady state. A possible evolution of the precursor particles up to the steady state was proposed. Both the precursors and the cathodes from these four different recycling streams exhibit similar morphology, particle size distribution, and tap density. Moreover, these recovered cathode materials display similar electrochemical properties. Surprisingly, these recovered NMC111s have better rate capability than a commercial NMC111 prepared from virgin materials. The different chemical compositions of the incoming recycling streams were shown to have little observed effect on the recovered precursor and resultant cathode material generated by the WPI-developed recycling process with advantages including no sorting, low temperature, and high quality recovered battery materials. Therefore, the WPI-developed process applies to different spent Li-ion battery waste streams and is, therefore, general.
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