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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Recovery of critical elements from end-of-life lithium ion batteries with supported membrane solvent extraction

Single-stage and multi-stage systems and methods for the recovery of critical elements in substantially pure form from lithium ion batteries are provided. The systems and methods include supported membrane solvent extraction using an immobilized organic phase within the pores of permeable hollow fibers. The permeable hollow fibers are contacted by a feed solution on one side, and a strip solution on another side, to provide the simultaneous extraction and stripping of elements from dissolved lithium ion cathode materials, while rejecting other elements from the feed solution. The single- and multi-stage systems and methods can selectively recover cobalt, manganese, nickel, lithium, aluminum and other elements from spent battery cathodes and are not limited by equilibrium constraints as compared to traditional solvent extraction processes.

Bhave, Ramesh R.↗
DOE OSTI2024

Enhancing Cycling Stability of Lithium Metal Batteries by a Bifunctional Fluorinated Ether

Abstract The lifespan of lithium (Li) metal batteries (LMBs) can be greatly improved by the formation of inorganic‐rich electrode‐electrolyte interphases (EEIs) (including solid‐electrolyte interphase on anode and cathode‐electrolyte interphase on cathode). In this work, a localized high‐concentration electrolyte containing lithium bis(fluorosulfonyl)imide (LiFSI) salt, 1,2‐dimethoxyethane (DME) solvent and 1,2‐bis(1,1,2,2‐tetrafluoroethoxy)ethane (BTFEE) diluent is optimized. BTFEE is a fluorinated ether with weakly‐solvating ability for LiFSI so it also acts as a co‐solvent in this electrolyte. It can facilitate anion decomposition at electrode surfaces and promote the formation of more inorganic‐rich EEI layers. With an optimized molar ratio of LiFSI:DME:BTFEE = 1:1.15:3, LMBs with a high loading (4 mAh cm −2 ) lithium nickel manganese cobalt oxide (LiNi 0.8 Mn 0.1 Co 0.1 ) cathode can retain 80% capacity in 470 cycles when cycled in a voltage range of 2.8–4.4 V. The fundamental understanding on the functionality of BTFEE revealed in this work provides new perspectives on the design of practical high‐energy density battery systems.

25 ENERGY STORAGE↗
DOE OSTI2022

Concealed Cathode Degradation in Lithium-Ion Cells with a Ni-Rich Oxide

Difficulties with sourcing cobalt and the interest in increasing cell energy have motivated the development of Ni-rich oxide materials for lithium-ion battery cathodes. Despite the intense research on the topic, there is limited information available on the long-term performance of novel cathode formulations. Here, we evaluate the stability of LiNi 0.9 Mn 0.05 Co 0.05 O 2 in full-cells tested for over five months, assessing how cycling, voltage and electrolyte additives impact cathode aging. We use differential voltage analysis to extract insights about the cathode from the full-cell data and identify the isolation of cathode particles in the delithiated (charged) state as a relevant mode of aging. Importantly, this particular mechanism of cathode aging does not cause immediate cell capacity fade, causing the simple analysis of cell capacity retention to overestimate the cathode stability under the investigated conditions. So, our observations serve as cautionary tale indicating that careful analysis of data from extended testing may be required for assessing the performance of Ni-rich cathodes and for evaluating how these materials are affected by electrolyte additives.

25 ENERGY STORAGE↗
DOE OSTI2023

Assessing the Intrinsic Roles of Key Dopant Elements in High–Nickel Layered Oxide Cathodes in Lithium–Based Batteries

A rational compositional design is critical for utilizing LiNiO 2 -based cathodes with Ni contents > 90% as promising next-generation cathode materials. Unfortunately, the lack of a fundamental understanding of the intrinsic roles of key elements, such as cobalt, manganese, and aluminum, makes the rational compositional design of high-Ni cathodes with a limited range of dopants (<10%) particularly challenging. Here, with 5% single-element doped cathodes, viz., LiNi 0.95 Co 0.05 O 2 , LiNi 0.95 Mn 0.05 O 2 , and LiNi 0.95 Al 0.05 O 2 , along with undoped LiNiO 2 (LNO), the influences of the dopants are systematically examined through a control of cutoff charge energy density and a common practice of cutoff charge voltage. Comprehensive investigations into the electrochemical properties, combined with in-depth analyses of the structural and interfasial stabilities and electrolyte decomposition pathways through advanced characterizations, unveil the following: i) the intrinsic role of dopants regulates the cathode energy density or state-of-charge and, more critically, the occurrence of H2–H3 phase transition, which essentially dictates cyclability; ii) undoped LNO can be stabilized well with the avoidance of H2–H3 phase transition; and iii) Co provides more merits overall with an optimized electrochemical operating condition. Finally, this work provides guidance for the compositional design of high-energy-density high-Ni cathodes and sheds light on the challenges of removing Co.

25 ENERGY STORAGE↗
DOE OSTI2023

Operation of Layered LiCoO 2 to Higher Voltages with a Localized Saturated Electrolyte

The commercialization of lithium-ion batteries started with the layered LiCoO 2 (LCO) cathode for portable electronics, but only 50% of its theoretical capacity can be used in practical cells due to detrimental surface and bulk degradations when charged to high voltages. Here we demonstrate here that the stability of electrolyte plays a critical role in the performance of LCO at high voltages by employing a localized saturated electrolyte (LSE). With a cutoff voltage of 4.5 V, LCO achieves an initial 1C discharge capacity of 176 mA h g -1 and a capacity retention of 80% over 230 cycles. Even with a cutoff voltage of 4.6 V, LCO with 2% aluminum doping displays an initial discharge capacity of 189 mA h g -1 at 1C rate with 80% capacity retention over 137 cycles. With extensive analytical characterization, we show that the improved cycling stability stems from a suppression of the O3 to H1-3 phase transition as well as a robust inorganic-rich cathode-electrolyte interphase (CEI) facilitated by the LSE. This work highlights the importance of protecting the surface as well as the bulk with appropriate electrolytes for the high-voltage, higher-energy-density operation of LCO.

25 ENERGY STORAGE↗
DOE OSTI2025

Primary material supply configurations and domestic recycling for cost-effective battery material production in the US

Battery cathode active material costs hinge on regionally concentrated, price-volatile metal supply. Here. we construct a regional facility-level cost model based on over 80 global lithium, cobalt, and nickel mines, refineries, and battery-grade material plants. Our model yields aggregated lithium, nickel, manganese, and cobalt production material costs from 392 region-based supply configurations for five different cathode active materials. Focusing on the United States, all-domestic supply is 9–34% costlier than global average, increasing by cobalt content, while these shortfalls can be overcome by selective low-cost material imports. Furthermore, we analyze costs of two U.S.-based recycling facilities from primary data and techno-economic modelling and compare resulting cathode active material-level costs to primary supply. Although it is still significantly higher on cathode active material cost-level, rising end-of-life flows and lowered black-mass prices will, however, make secondary supply cost-competitive to domestic and foreign primary supply cost floors. Facility-level benchmarks reveal targeted import, scaling, and production cost optimization as levers for a resilient, cost-effective U.S. battery-material supply chain.

Energy↗
DOE OSTI2022

Expression Patterns of Energy-Related Genes in Single Cells Uncover Key Isoforms and Enzymes That Gain Priority Under Nanoparticle-Induced Stress

Cellular responses to nanoparticles (NPs) have been largely studied in cell populations, providing averaged values that often misrepresent the true molecular processes that occur in the individual cell. To understand how a cell redistributes limited molecular resources to achieve optimal response and survival requires single-cell analysis. Here we applied multiplex single molecule-based fluorescence in situ hybridization (fliFISH) to quantify the expression of 10 genes simultaneously in individual intact cells, including glycolysis and glucose transporter genes, which are critical for restoring and maintaining energy balance. We focused on individual gill epithelial cell responses to lithium cobalt oxide (LCO) NPs, which are actively pursued as cathode materials in lithium-ion batteries, raising concerns about their impact on the environment and human health. We found large variabilities in the expression levels of all genes between neighboring cells under the same exposure conditions, from only a few transcripts to over 100 copies in individual cells. Gene expression ratios among the 10 genes in each cell uncovered shifts in favor of genes that play key roles in restoring and maintaining energy balance. Among these genes are isoforms that can secure and increase glycolysis rates more efficiently, as well as genes with multiple cellular functions, in addition to glycolysis, including DNA repair, regulation of gene expression, cell cycle progression, and proliferation. Our study uncovered prioritization of gene expression in individual cells for restoring energy balance under LCO NP exposures. Broadly, our study gained insight into single-cell strategies for redistributing limited resources to achieve optimal response and survival under stress.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Cost‐Effective Layered Oxide – Olivine Blend Cathodes for High‐Rate Pulse Power Lithium‐Ion Batteries

Abstract Sustainability and supply‐chain concerns require lithium‐ion batteries (LIBs) free from critical minerals, such as nickel and cobalt. While recent advances provide encouraging signs that cobalt can be removed, the question remains how much Ni can be removed from Co‐free layered oxide cathodes before sacrificing critical performance metrics. This study highlights the effect of reducing Ni by benchmarking several Co‐free cathodes with decreasing Ni content. Keeping the energy density the same by increasing the charge voltage, cathodes below 80% Ni content exhibit worsened capacity fade due to increasing oxygen release and electrolyte decomposition. Charge transfer and diffusion kinetics are also hindered with increasing Mn content and exacerbated by resistive surface phases formed at high voltages, rendering lower‐Ni, Co‐free cathodes less competitive than high‐Ni cathodes for high energy and power applications. It is demonstrated blending layered oxide with olivine as an effective alternative to deliver energy density and cycling stability comparable to lower‐Ni cathodes with moderate charging voltages. Blending with 30 wt% olivine LiMn 0.5 Fe 0.5 PO 4 (LMFP) virtually eliminates the diffusion limitation of layered oxides at low state‐of‐charge, with enhanced pulse power characteristics rivaling the high‐Ni counterparts. Cathode blending can further reduce the overall Ni content and cost without the performance limitations of lower‐Ni, Co‐free cathodes.

Lee, Steven↗
DOE OSTI2020

Degradation & Performance Studies of ALD-Stabilized Nano-Composite SOFC Cathodes

This work showed, definitively, for the first time, that zirconia Atomic Layer Deposited (ALD) overcoats improve the stability of Solid Oxide Fuel Cell (SOFC) cathodes by chemically gettering interfacial Sr that has segregated out of lanthanum strontium cobalt iron oxide (LSCF). The optimum ALD ZrO 2 overcoat thickness was found to be ≥5 nm and <10 nm. Gadolinium doped ceria (GDC) pre-infiltration was also shown, for the first time, to improve SOFC cathode stability through the chemical getting of Sr at the LSCF-backbone and LSCF-gas interfaces. Due to the fact that it can be performed easily in air on large-area electrodes, GDC pre-infiltration is likely more commercially viable than ALD ZrO 2 overcoating as an interfacial Sr gettering technique. Combining ZrO 2 overcoating with GDC pre-infiltration was not successful because the GDC nano-particles gettered the ZrO 2 overcoat instead of the interfacial Sr.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Lithium Ion Cathode Materials Prepared Using Glycerol as Solvent and Reactant

Two different types of cathode materials were prepared using glycerol as a solvent and reactant. The LiMn1/3Ni1/3Co1/3O2 layered oxide cathode material was successfully synthesized with a shorter time of heat treatment of 8hr at 900°C. An appreciated capacity retention of 83.7% after 100 cycles with an initial discharge capacity of 177.1 mAh/g at 0.1C (discharge rate) has been achieved. Another cathode material with the formula of Li1.2 Mn0.51Ni0.145+xCo0.145-xO2 (x=0 (LR2), 0.0725 (LR1)), as a Li-rich cathode material, has been also successfully synthesized using glycerol. It was shown that LR1 discharge capacity was increased from 185 to 213 mAh/g after 20 cycles and ended up with 194.9 mAh/g after 60 cycles at 0.1C (discharge rate). This material shows an exceptional discharge capacity retention, lower toxic cobalt component, and lower production cost comparing with other Li-rich cathode materials. Detailed results of powder material synthesis, characterization, and battery testing will be presented to demonstrate that glycerol as a green solvent in the synthesis of battery materials.

25 ENERGY STORAGE↗
DOE OSTI2021

Reactive boride infusion stabilizes Ni-rich cathodes for lithium-ion batteries

Engineered polycrystalline electrodes are critical to the cycling stability and safety of lithium-ion batteries, yet it is challenging to construct high-quality coatings at both the primary- and secondary-particle levels. Here, we present a room-temperature synthesis route to achieve full surface coverage of secondary particles and facile infusion into grain boundaries, thus offering a complete “coating-plus-infusion” strategy. Cobalt boride metallic glass is successfully applied to Ni-rich layered cathode LiNi 0.8 Co 0.1 Mn 0.1 O 2 . Here, it dramatically improves the rate capability and cycling stability, including under high-discharge-rate and elevated-temperature conditions and in pouch full cells. The superior performance originates from simultaneous suppression of microstructural degradation of intergranular cracking and side reactions with electrolyte. Atomistic simulations identified the critical role of strong selective interfacial bonding, which offers not only a large chemical driving force to ensure uniform reactive wetting and facile infusion but also lowered the surface/interface oxygen activity, contributing to the exceptional mechanical and electrochemical stabilities of the infused electrode.

25 ENERGY STORAGE↗
DOE OSTI2023

Low cobalt layered oxide materials for lithium ion battery electrodes

Stabilized layered lithium metal oxide cathode materials are described which include excess lithium, Ni, Mn, and at least one other metal ion. The materials comprise a layered LiMO 2 -type material in which M comprises a combination of Ni, Mn, and at least one other metal ion that includes less than about 6 mol % Co; and which has about 1 to 6 percent excess lithium. In one embodiment, the stabilized lithium metal oxide cathode material comprises a composition having the empirical formula xLi 2 MnO 3 ·(1−x)LiNi 0.5+δ/2 Mn 0.5−δ Co δ/2 O 2 , wherein 0 1+3y [Ni a Mn b M′ c ] 1−y O 2 , wherein M′ is one of more metal selected from the group consisting of Co, Al, Fe, Mg, and Ti; 0<y≤0.02; 0.85≤a≤0.96; 0.03≤b≤0.1; and 0.01≤c≤0.1.

Croy, Jason R.↗
DOE OSTI2022

Paving Pathways Toward Long–Life Graphite/LiNi 0.5 Mn 1.5 O 4 Full Cells: Electrochemical and Interphasial Points of View

The high-voltage spinel cathode LiNi 0.5 Mn 1.5 O 4 (LNMO) with no cobalt and low nickel content is promising for lithium-ion batteries due to its high energy and power densities, good thermal stability, and low cost. However, its high operating voltage (≈4.7 V) results in a decomposition of the electrolyte, severe chemical crossover, and deterioration of electrode-electrolyte interphases (EEIs), hindering its practical viability. It is demonstrated here that by electrochemically pre-cycling the graphite in an electrolyte containing 30 wt.% fluoroethylene carbonate, a robust LiF-rich artificial solid electrolyte interphase can be constructed for surface protection; on the other hand, an electrochemical pre-lithiation of Fe-doped LNMO serves as a lithium source for graphite at a full-cell voltage of 2.6 V. As a result, the full cells with the as-modified electrodes deliver a high capacity of 129 mA h g –1 with an excellent capacity retention of 93% after 200 cycles, vastly outperforming the full cells with fresh electrodes (120 mA h g –1 initial capacity with 78% retention). Lastly, pathways toward long-life graphite||LNMO full cells are pictured based on the inspirations from the electrochemical modifications and in-depth analyses of the EEIs in this study.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Metal–Organic Framework-derived Atomic Metal Sites Promoting Sulfur Cathode for All-Solid-State Lithium–Sulfur Batteries

All-solid-state lithium–sulfur batteries (ASSLSBs) offer high energy density and intrinsic safety; however, they still face major challenges, including sluggish redox kinetics and poor sulfur utilization. Incorporating conductive materials into sulfur cathodes is an effective strategy to mitigate these limitations. Here, a highly conductive cobalt–nitrogen–doped carbon (Co–NC) derived from a metal–organic framework (MOF) is introduced to accelerate charge transfer and promote reversible sulfur conversion. Co−NC provides atomically dispersed Co–N sites and conductive carbon pathways that correlate with improved charge transfer, sulfur utilization, and rate capability. Co–NC@S cathode delivers 1499 mAh g–1 at C/20 with a high sulfur loading (5 mg cm–2) and retains 1292 mAh g–1 after five cycles (vs 443 mAh g–1 without Co–NC). Moreover, Co–NC derived ASSLSB achieves 903 mAh g–1 at 5C at 60 °C. This work provides a practical and effective approach to develop high energy, high-rate ASSLSBs.

25 ENERGY STORAGE↗
DOE OSTI2024

The Role and Substitution of Cobalt in the Cobalt‐Lean/Free Nickel‐Based Layered Transition Metal Oxides for Lithium Ion Batteries

Here, the Nickel-based layered transition metal oxide cathode represented by NCM (LiNi x Co y Mn z O 2 , x+y+z=1) and NCA (LiNi x Co y Al z O 2 , x+y+z=1) is widely used in the electric vehicle market due to its specific capacity and high working potential, in which Cobalt (Co) plays a huge role in improving the structural stability during the cycle. However, the limited supply of Co, due to its scarcity and the influence of geopolitics, poses a significant constraint on the further advancement of the Nickel-based layered transition metal oxide cathode in the field of energy storage. In this paper, the mechanism of Co in the Nickel-based layered transition metal oxides is reviewed, including its critical role for structural stability such as the inhibition of cationic mixing and the release of lattice oxygen et al. Subsequently, it outlines various strategies to enhance the performance of Co-lean/free materials, such as ion doping, including single-ion doping and multi-ion co-doping, and various surface coating strategies, so as to eliminate the adverse effects of Co loss on materials. Ultimately, this paper offers a glimpse into the promising future of Cobalt-free strategies for high performance of Nickel-based layered transition metal oxides.

25 ENERGY STORAGE↗
DOE OSTI2026

A technoeconomic analysis of poly- and single-crystalline NMCxyz from material synthesis to battery pack design

A process model was developed for estimating the cost of manufacturing lithium nickel manganese cobalt oxide (LiNi x Mn y Co z O 2 , NMCxyz), the main cathode active material in lithium-ion batteries used for electric vehicles in the United States. The model was used to estimate the prices of NMC622, NMC811, and NMC955 with poly- and single-crystalline morphologies. The Battery Performance and Cost Model (BatPaC) was used to translate the NMC prices into battery pack prices. A decrease in cobalt content from NMC622 (20% Co) to NMC955 (5% Ni) decreases the material price by $\$$0.85/kg (−3%) due to a decrease in the cost of battery materials, which account for >60% of the total price. NMC622 only produce cheaper packs if the nickel sulfate cost is > 4 × its baseline, indicating higher nickel materials will lower pack cost under normal market conditions. Single-crystalline materials are $\$$2/kg (+8%) more expensive than their polycrystalline counterparts due to higher manufacturing costs from longer, hotter calcinations in less densely packed saggars. This increases the pack price by ∼$\$$3/kWh, assuming identical electrochemical properties. In conclusion, the single-crystalline materials could yield cheaper packs if cycled to higher upper cutoff voltages (i.e., 4.35 to 4.43 V for the single-crystalline material vs. 4.25 V for their polycrystalline counterparts).

Cost modeling↗
DOE OSTI2024

Enhancing the Reaction Kinetics and Stability of Co‐Free Li‐Rich Cathode Materials via a Multifunctional Strategy

Co-free Li-rich layered oxides (CFLLOs) with anionic redox activity are among the most promising cathode materials for high-energy-density and low-cost lithium-ion batteries (LIBs). However, irreversible oxygen release often causes severe structural deterioration, electrolyte decomposition, and the formation of unstable cathode-electrolyte interface (CEI) film with high impedance. Additionally, the elimination of cobalt elements further deteriorates the reaction kinetics, leading to reduced capacity and poor rate performance. Here, in this study, a multifunctional strategy is proposed, incorporating Li 2 MnO 3 phase content regulation, micro-nano structure design, and heteroatom substitution. The increased content of Li 2 MnO 3 phase enhances the capacity through oxygen redox. The smaller nanoscale primary particles induce greater tensile strain and introduce more grain boundaries, thereby improving the reaction kinetics and reactivity, while the larger micron-sized secondary particles help to reduce interfacial side reactions. Furthermore, Na⁺ doping modulates the local coordination environment of oxygen, stabilizing both the anion framework and the crystal structure. As a result, the designed cathode exhibits enhanced rate performance, delivering a capacity of 158 mAh g⁻¹ at 5.0 C and improved cyclic stability, with a high capacity retention of 99% after 400 cycles at 1.0 C. This multifunctional strategy holds great promise for advancing the practical application of CFLLOs in next-generation LIBs.

Co-free Li-rich layered oxide↗
DOE OSTI2023

Ab initio study of short-range ordering in vanadium-based disordered rocksalt structures

Disordered rocksalt Li-excess (DRX) compounds are attractive new cathode materials for Li-ion batteries as they contain resource-abundant metals and do not require the use of cobalt or nickel. Understanding the delithiation process and cation short-range ordering (SRO) in DRX compounds is essential to improve these promising cathode materials. Herein, we use first-principles calculations along with the cluster-expansion approach to model the disorder in DRX Li 2-x VO 3 , 0 < x < 1. We discuss the SRO of Li in tetrahedral and octahedral sites, and the order in which Li delithiates and V oxidizes with respect to local environments. We reveal that the number of nearest-neighbor V dictates the order of delithiation from octahedral sites and that V is oxidized in a manner that minimizes the electrostatic interactions among V. In conclusion, our results provide valuable insight for tailoring the performance of V-based DRX cathode materials in general by controlling the SRO features that reduce energy density.

36 MATERIALS SCIENCE↗