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DOE OSTI2025

Selectively extracting lithium from single and mixed cathode materials

With the burgeoning reliance on lithium-ion batteries for sustainable energy solutions and electric transportation, the environmental and resource management associated with battery disposal are increasingly critical. Addressing these challenges necessitates innovative recycling techniques that recover valuable battery components, particularly lithium. This research introduces a universal, eco-friendly approach tailored for the efficient selective extraction of lithium from both single and mixed cathode materials, achieving impressive selective leaching efficiencies of lithium (99.51 % for LFP, 90 % for NMC, and 97.24 % for mixed cathode). Surprisingly, leaching efficiency of lithium from NMC can be significantly improved by introducing LFP since LFP can remove the dense transition-metal salts on the surface of NMC. The extracted lithium is recovered as lithium carbonate with battery-grade purity. This study also highlights the reuse of formic acid and the adoption of oxygen as an oxidizing agent to prevent wastewater production. Therefore, this method provides a robust foundation for sustainable lithium battery recycling.

economically and environmentally feasible↗

DOE OSTI2026

Upcycling mixed cathode materials to high-energy-density LiFe 0.75 Mn 0.25 PO 4

To address the demand for next-generation cathode materials with high energy density, upcycling LiFePO 4 into LiFe 0.75 Mn 0.25 PO 4 has attracted considerable attention. Nevertheless, existing strategies have yet to achieve both morphology and full elemental recovery under mild ambient conditions. Here, we report an upcycling route that can address this issue by combining leaching and a high-temperature treatment process. The upcycled LiFe 0.75 Mn 0.25 PO 4 exhibits enlarged lattice spacing and a high discharge plateau, and it delivers an energy density of 563.7 Wh/kg, 40.3 Wh/kg higher than recycled LiFePO 4 , which indicates the high value of the proposed upcycling strategy. At 1 C, LiFe 0.75 Mn 0.25 PO 4 also exhibits excellent cycling stability of 91% over 700 cycles. Techno-economic analysis also indicates impressive economic and environmental benefits, including 10.4% less raw materials usage and 12.2% less energy consumption and wastewater generation. This work demonstrates a scalable and economic upcycling strategy and provides a promising pathway for sustainable battery upcycling compatible with industrial conditions.

LMFP↗

DOE OSTI2020

Rational Designed Mixed-Conductive Sulfur Cathodes for All-Solid-State Lithium Batteries

All-solid-state lithium–sulfur batteries (ASSLSBs) hold great promise for safe and high-energy-density energy storage. However, developing high-performance sulfur cathodes has been proven difficult due to low electronic and ionic conductivities and large volume change of sulfur during charge and discharge. Here, we reported an approach to synthesize sulfur cathodes with a mixed electronic and ionic conductivity by infiltrating a solution consisting of Li 3 PS 4 (LPS) solid electrolyte and S active material into a mesoporous carbon (CMK-3). This approach leads to a uniform dispersion of amorphous Li 3 PS 7 (L 3 PS) catholyte in an electronically conductive carbon matrix, enabling high and balanced electronic/ionic conductivities in the cathode composite. The inherent porous structure of CMK-3 also helps to accommodate the strain/stress generated during the expansion and shrinkage of the active material. In sulfide-based all-solid-state batteries with Li metal as the anode, this cathode composite delivered a high capacity of 1025 mAh g –1 after 50 cycles at 60 °C at 1/8C. This work highlights the important role of high and balanced electronic and ionic conductivities in developing high-performance sulfur cathodes for ASSLSBs.

25 ENERGY STORAGE↗

DOE OSTI2022

Carbon dioxide treatment of cathodes

A method for producing water resistant cathodes is discussed. The method uses mixing cathode powder with solid carbon dioxide to create a mixture and heating the mixture to a temperature. The heating occurs for a time sufficient to cause lithium carbonate coatings to form on the powder. A method for coating lithium-containing cathode surfaces is also discussed. This method uses simultaneously sublimating solid CO 2 and condensing atmospheric water vapor onto surfaces. Afterwards allowing the lithium to react with the sublimated CO 2 for a time sufficient to create a lithium carbonate film on the surface.

Kahvecioglu, Ozgenur↗

DOE OSTI2021

Direct Recycling of Blended Cathode Materials by Froth Flotation

We report that direct Li-ion battery recycling involves separating cathode active materials in the solid phase while preserving their electrochemical performance. To reuse the recycled ones in new batteries, it is necessary to separate individual cathode components, which would typically occur prior to the rejuvenation and any compositional reformulation processes. Herein, a froth flotation process is developed to separate pristine lithium nickel-manganese-cobalt oxide (LiNi 0.333 Mn 0.333 Co 0.333 O 2 , NMC111) and lithium manganese oxide (LMO) materials. The flotation results show that with multiple stages of the separation processes, a satisfactory separation is achieved with 95% grade or above of NMC111 in the froth product and 95% grade of LMO in the tailing product. The electrochemistry results show that the flotation chemicals have negligible impact on the electrochemical performance of recycled active materials, whereas the NMC111 exhibits a minor capacity fade after being in contact with deionized water at 2% solid concentration. An improvement in both the rate and cycling performance is achieved at 10% solid concentration or higher. It is found that there is little compositional and structural change to the aqueous recycled NMC111 powders. An effective and low-cost separation method for direct recycling mixed cathode compositions is demonstrated.

25 ENERGY STORAGE↗

DOE OSTI2023

Nanoscale chemical imaging with structured X-ray illumination

High-resolution imaging with compositional and chemical sensitivity is crucial for a wide range of scientific and engineering disciplines. Although synchrotron X-ray imaging through spectromicroscopy has been tremendously successful and broadly applied, it encounters challenges in achieving enhanced detection sensitivity, satisfactory spatial resolution, and high experimental throughput simultaneously. In this work, based on structured illumination, we develop a single-pixel X-ray imaging approach coupled with a generative image reconstruction model for mapping the compositional heterogeneity with nanoscale resolvability. This method integrates a full-field transmission X-ray microscope with an X-ray fluorescence detector and eliminates the need for nanoscale X-ray focusing and raster scanning. We experimentally demonstrate the effectiveness of our approach by imaging a battery sample composed of mixed cathode materials and successfully retrieving the compositional variations of the imaged cathode particles. Bridging the gap between structural and chemical characterizations using X-rays, this technique opens up vast opportunities in the fields of biology, environmental, and materials science, especially for radiation-sensitive samples.

Li, Jizhou↗

DOE OSTI2025

Upcycling Mixed Spent Ni-Lean Cathodes into Ni-Rich Polycrystalline Cathodes

Sustainable battery recycling is vital for conserving resources and reducing environmental impacts. Current open- and closed-loop recycling strategies often focus on recovering individual components, making the reuse of mixed cathode materials a complex challenge. Meanwhile, the research on upcycling has been limited to using pristine cathode feedstocks and virgin materials for synthesis. Here, to address this issue, we present an upcycling approach for spent Ni-lean mixed cathode materials that integrate an upcycling hydrometallurgical recycling process with traditional hydrometallurgical methods. This strategy achieves a utilization of 92.31 mol % of recycled materials, enabling the regeneration of Ni-rich cathode materials while significantly reducing the reliance on virgin resources. The regenerated 83Ni cathode materials demonstrate physical properties comparable to those produced from virgin materials. Electrochemical evaluations using single-layer pouch cells show that both recycled and virgin cathodes exhibit initial specific capacity close to 201.1 mAh/g and maintain approximately 88 % capacity retention after 500 cycles. Additionally, 2Ah cells confirmed these findings, delivering 85 % capacity retention after about 900 cycles. Techno-economic analysis demonstrates notable environmental benefits, including reductions in greenhouse gas emissions and energy consumption, achieving 232.75 MJ/kg of product, which is 8.6 % lower than traditional methods and comparable to direct upcycling. Furthermore, the upcycling hydrometallurgical recycling process generates the highest profit, proving its economic viability. This scalable and versatile process is adaptable to varying transition metal compositions, facilitating a closed-loop recycling system that bridges mixed spent cathodes with next-generation cathode materials, and offers a sustainable solution for managing waste battery materials.

Hydrometallurgical recycling↗

NASA NTRS1985

Elastomeric Cathode Binder

Soluble copolymer binder mixed with cathode material and solvent forms flexible porous cathode used in lithium and Ni/Cd batteries. Cathodes prepared by this process have lower density due to expanding rubbery binder and greater flexibility than conventional cathodes. Fabrication procedure readily adaptable to scaled-up processes.

Yen, S. P. S.↗

NASA NTRS1972

Cathode for use with low density gases

Method for preventing deterioration of mixed oxide cathodes in low density gas tubes caused by ion bombardment is discussed. Construction of cathode is described and illustration is furnished. Electron emission through space charge to neutralize ion-filled regions is basic process.

Bennett, W. H.↗

DOE OSTI2024

Direct regeneration of lithium ion cathodes by ionothermal relithiation

A method for relithiating cathode material from spent lithium-based batteries, the method comprising: (i) mixing delithiated cathode material and a lithium salt with an ionic liquid in which the lithium salt is at least partially soluble to form an initial mixture; (ii) heating the initial mixture to a temperature of 100° C. to 300° C. to result in relithiation of the delithiated cathode material; and (iii) separating the ionic liquid from the relithiated cathode material; wherein, in embodiments, the cathode material is a lithium metal oxide, wherein the metal is selected from the group consisting of Ni, Co, Fe, Mn, Al, Zr, Ti, Nb, and combinations thereof, or wherein the cathode material has the formula LiNi x Mn y Co z O 2 , wherein x>0, y>0, z>0, and x+y+z=1; wherein, in some embodiments, the ionic liquid has a nitrogen-containing cationic portion, such as an imidazolium ionic liquid.

Luo, Huimin↗

DOE OSTI2020

Long-Term Cyclability of NCM-811 at High Voltages in Lithium-Ion Batteries: an In-Depth Diagnostic Study

High-nickel layered oxides, such as LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NCM-811), offer higher energy density than their low-nickel counterparts at a given voltage and are gaining major traction in automotive lithium-ion batteries for electric vehicles. Besides high-Ni content, higher charging voltages above 4.3 V vs Li + /Li boost the energy and represent another focus in battery development. Here, we investigate the long-term cyclability of NCM-811 in graphite pouch cells over 1000 deep cycles between 2.5–4.2, 2.5–4.4, and 2.5–4.5 V through a suite of sensitive characterization techniques. The NCM-811 full cells show severely deteriorated cyclability with higher charging voltages, from 78% at 4.2 V to 52 and 32% at 4.4 and 4.5 V, respectively. At 4.2 V, minor parasitic electrolyte oxidation as well as cathode Li/Ni mixing and cracking are revealed after cycling, while transition-metal dissolution and surface reconstruction into rock-salt NiO are virtually undetectable. At 4.4 and 4.5 V, transition-metal dissolution and crossover to the anode become much more pronounced and a primary contributor to the capacity fade, while significant surface NiO formation causes substantial voltage polarization, which is less noticeable at 4.2 V. Meanwhile, more severe electrolyte oxidation, Li/Ni mixing, and particle pulverization exacerbate the voltage and capacity fade. Finally, these results outline distinct challenges for stable high-Ni layered oxide cathodes in high-voltage Li-ion batteries.

25 ENERGY STORAGE↗

DOE OSTI2022

High‐Performance and Durable Fuel Cells using Co/Sr‐Free Fluorite‐Based Mixed Conducting (Pr,Ce)O 2‐δ Cathode

Abstract A major challenge to overcome in demonstrating solid oxide fuel cells (SOFCs) to be suitable as efficient and environmentally friendly energy conversion devices capable of addressing pressing clean energy and environmental needs is to surmount chemical and thermo‐mechanical instabilities in their operational phase. To date, perovskite‐based mixed conducting cathodes, which include inherent Co and Sr elements for enhanced reactivity and conductivity, have been intensively studied. These Co/Sr‐based oxides, however, exhibit severe thermochemical expansion and suffer from Sr surface segregation, ultimately degrading the electrode performance. Here, high‐performance and durable SOFCs are demonstrated by employing a Co/Sr‐free fluorite‐based mixed conducting (Pr,Ce)O 2‐δ (PCO) cathode eminently compatible with fluorite‐based solid electrolytes. The nanocolumnar PCO electrode developed in this study provides not only a remarkable low level of electrode resistance (e.g., ≈0.05 Ω cm 2 at 600 °C) but also exceptional long‐term stability (e.g., a degradation rate 15 times slower compared to the state‐of‐the‐art La 0.6 Sr 0.4 CoO 3‐δ perovskite). The competitive peak power densities of an anode‐supported single cell with the PCO cathode are also successively achieved, recording a value of 0.92 W cm −2 at 600 °C. These findings herald the development of new Co/Sr‐free electrodes for SOFCs at intermediate temperatures.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Na 4 Fe 1.5 Mn 1.5 (PO 4 ) 2 (P 2 O 7 ): A low-cost and earth-abundant cathode for robust sodium storage

The mixed compounds of phosphates and pyrophosphates are attractive cathodes for sodium-ion batteries (SIBs) owing to their robust open framework structure and superior diffusion dynamics. However, most reported mixed phosphate cathodes generally suffer from low operating potential. Herein, we develop a bimetallic Na 4 Fe 1.5 Mn 1.5 (PO 4 ) 2 (P 2 O 7 )/C-rGO (NFMPP/C-rGO) cathode, which possesses two working plateaus at 2.92 and 3.95 V. The obtained NFMPP/C-rGO demonstrates a stable high capacity of over 120 mAh g −1 at 0.1 C. In-situ XRD characterization discloses a solid solution reaction for the Fe 2+/3+ redox couple and a two-phase reaction for the Mn 2+/3+ redox couple. In conclusion, first-principles calculations reveal the migration of Na + in NFMPP has low barriers. This work provides a new, low-cost, earth-abundant, and stable cathode choice for practical SIBs.

Cathode materials↗

NASA NTRS1979

The alkaline zinc electrode as a mixed potential system

Cathodic and anodic processes for the alkaline zinc electrode in 0.01 molar zincate electrolyte (9 molar hydroxide) were investigated. Cyclic voltammograms and current-voltage curves were obtained by supplying pulses through a potentiostat to a zinc rotating disk electrode. The data are interpreted by treating the system as one with a mixed potential; the processes are termed The zincate and corrosion reactions. The relative proportions of the two processes vary with the supplied potential. For the cathodic region, the cathodic corrosion process predominates at higher potentials while both processes occur simultaneously at a lower potential (i.e., 50 mV). For the anodic region, the anodic zincate process predominates at higher potentials while the anodic corrosion process is dominant at lower potential (i.e., 50 mV) if H2 is present.

Fielder, W. L.↗

NASA NTRS2002

In-FEEP ion beam neutralization with thermionic and field emission cathodes

Charge neutralization of an In-FEEP thruster was demonstrated with three different electron sources by zeroing the floating potential of the thruster and neutralizer system. The three cathodes used in the investigation include a mixed metal thermionic cathode, a carbon nanotube field emission cathode, and a Spindt-type Mo field emission array cathode.

field emission cathodes FEEP electric propulsion↗

DOE OSTI2021

Mixed Cationic and Anionic Redox in Ni and Co Free Chalcogen-Based Cathode Chemistry for Li-Ion Batteries

Mixed cationic and anionic redox cathode chemistry is emerging as conventional cationic-redox of transition metal based layered oxides are reaching their theoretical capacity limit. However, these anionic redox in transition metal oxide-based cathodes attained by taking excess lithium has resulted in stability issues due to weak metal - oxygen ligand covalency. Here, we present an alternative approach of improving metal - ligand covalency by introducing less electronegative chalcogen ligand (sulfur) in the cathode structural framework where the metal dband penetration into ligand p-band thereby utilizing reversible mixed anionic and cationic redox chemistry. Through this design strategy, we report possibility of developing a new family of layered cathode materials when partially filled d orbital redox couples like Fe 2+/3+ are introduced in the Li-ion conducting phase (Li 2 SnS 3 ). Further, the electron energy loss spectroscopy (EELS) and X-ray absorption near-edge structure (XANES) analysis are used to qualitatively identify the charge contributors at the metal and ligand sites during Li + extraction. The detailed high-resolution transmission electron microscopy (HR-TEM) and high annular dark field-scanning transmission electron microscopy (HAADF-STEM) investigation reveal the multi redox induced structural modifications and its surface amorphization with nanopore formation during cycling. Findings from this study will shed light on designing Ni and Co free chalcogen cathodes and various functional materials in the chalcogen based dual anionic and cationic redox cathode avenue.

25 ENERGY STORAGE↗

NASA NTRS1989

Advances in ambient temperature secondary lithium cells

The Jet Propulsion Laboratory is involved in a Research and Development program sponsored by NASA/OAST on the development of ambient temperature secondary lithium cells for future space applications. Some of the projected applications are planetary spacecraft, planetary rovers, and astronaut equipment. The main objective is to develop secondary lithium cells with greater than 100 Wh/kg specific energy while delivering 1000 cycles at 50 percent Depth of Discharge (DOD). To realize these ambitious goals, the work was initially focused on several important basic issues related to the cell chemistry, selection of cathode materials and electrolytes, and component development. The performance potential of Li-TiS2, Li-MoS3, Li-V6O13 and Li-NbSe3 electrochemical systems was examined. Among these four, the Li-TiS2 system was found to be the most promising system in terms of realizable specific energy and cycle life. Some of the major advancements made so far in the development of Li-TiS2 cells are in the areas of cathode processing technology, mixed solvent electrolytes, and cell assembly. Methods were developed for the fabrication of large size high performance TiS2 cathodes. Among the various electrolytes examined, 1.5M LiAsF6/EC + 2-MeTHF mixed solvent electrolyte was found to be more stable towards lithium. Experimental cells activated with this electrolyte exhibited more than 300 cycles at 100 percent Depth of Discharge. Work is in progress in other areas such as selection of lithium alloys as candidate anode materials, optimization of cell design, and development of 5 Ah cells. The advances made at the Jet Propulsion Laboratory on the development of secondary lithium cells are summarized.

Subbarao, S.↗

DOE OSTI2020

Mixed Ionic–Electronic Conductor of Perovskite Li x La y MO 3-δ toward Carbon-Free Cathode for Reversible Lithium–Air Batteries

Mixed ionic–electronic conductors (MIECs) can play a pivotal role in achieving high energies and power densities in rechargeable batteries owing to their ability to simultaneously conduct ions and electrons. In our study, a new strategy is proposed wherein late 3d transition metals (TMs) are substituted into a perovskite Li-ion conductor to transform it into a Li-containing MIEC. First-principles calculations show that perovskite Li x La y MO 3 with late 3d TMs have a low oxygen vacancy formation energy, implying high electron carrier concentrations corresponding to high electronic conductivity. The activation barriers for Li diffusion in Li x La y MO 3 (M = Ti, Cr, Mn, Fe, and Co) are below 0.411 eV, resulting in high Li-ion conductivity. The designed perovskites of Li0.34La 0.55 MnO 3-δ experimentally prove to have high electronic (2.04 × 10 -3 S cm -1 ) and Li-ion (8.53 × 10 -5 S cm -1 ) conductivities, and when applied in a carbon-free cathode of a Li–air cell, they deliver superior reversibility at 0.21 mAh cm -2 over 100 charge/discharge cycles while avoiding the degradation associated with carbonaceous materials. Finally, this strategy enables the effective design of Li-conducting MIEC and reversible Li–air batteries.

36 MATERIALS SCIENCE↗