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Review Issue
Recycling of Spent Graphite Anode Materials from Lithium-Ion Batteries
Journal of the Chinese Ceramic Society 2025, 53(8): 2194-2209
Published: 29 May 2025
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Downloads:35

The global transition toward renewable energy and electric vehicles has triggered exponential growth in lithium-ion batteries (LIBs), resulting in a surge of retired batteries. As the predominant anode material in LIBs, graphite accounts for a significant mass proportion of batteries. However, improper disposal of spent graphite (S-Gr) through incineration or landfilling poses severe environmental risks, including particulate emissions and toxic residue release. Recycling S-Gr is critical to alleviating resource shortages, reducing production costs of high-purity graphite (which requires energy-intensive graphitization processes at 2500–3000 ℃), and achieving sustainable development goals. This review focuses on the failure mechanisms, recycling strategies, and reuse pathways of S-Gr, providing key insights for advancing closed-loop battery ecosystems.

The degradation of graphite anodes during LIB cycling originates from multiscale failure mechanisms. Deterioration of the solid electrolyte interphase (SEI) caused by chemical decomposition, mechanical stress, and thermal instability leads to irreversible lithium loss and capacity fade. Concurrently, lithium dendrite growth on graphite surfaces increases internal short-circuit risks, while repeated Li+ intercalation/deintercalation induces microcracks and structural collapse of graphite layers. These coupled mechanisms initiate a vicious cycle of performance degradation, highlighting the necessity for tailored recycling approaches.

Current recycling technologies focus on efficient separation and purification of S-Gr. Physical methods (e.g., flotation and sieving) achieve preliminary separation but suffer from impurity retention (purity <73.56%). Innovative techniques such as Fenton reagent-assisted flotation and pyrolysis-ultrasonic synergy enhance recovery efficiency, but face scalability challenges. Hydrometallurgical processes utilizing HCl, H2SO4, or organic acids (e.g., citric acid) effectively leach impurities like Li, Al, and Fe but generate corrosive waste. Pyrometallurgical approaches (e.g., inert atmosphere calcination and catalytic graphitization) restore graphite crystallinity but demand high energy consumption (>2600 ℃) and emit hazardous gases. Hybrid strategies combining hydrometallurgical treatment with high-temperature annealing emerge as promising solutions.

Regenerated S-Gr demonstrates versatility in energy storage and functional applications. For secondary batteries, carbon-modified S-Gr via rapid thermal shock or phenolic resin coating exhibits superior performance in LIBs. In sodium/potassium-ion batteries, defect-engineered S-Gr shows enhanced kinetics and stability. Beyond energy storage, S-Gr can be transformed into high-value materials. Advanced applications include graphene production through lithium-intercalation exfoliation and catalytic composites for environmental remediation.

Summary and prospects

Despite progress, critical challenges persist. The heterogeneity of S-Gr sources (natural, synthetic, or composite graphite) complicates standardized recycling. High costs, toxic emissions (e.g., fluorine), and intensive energy-consuming steps hinder process scalability. Future directions should prioritize intelligent sorting systems, AI-driven process optimization, and green alternatives like bioleaching. Integrating ultrasound, microwave, or electrochemical technologies could streamline processes and reduce energy consumption. Expanding S-Gr applications (e.g., flexible electronics, CO2 capture, and defect-engineered catalysts) requires interdisciplinary innovation. Addressing these issues will accelerate commercialization of S-Gr recycling technologies, promote sustainable battery ecosystems, and advance global carbon neutrality goals.

Open Access Research Article Issue
Low-Strain and High-Energy KVPO4F Cathode with Multifunctional Stabilizer for Advanced Potassium-Ion Batteries
Energy & Environmental Materials 2024, 7(5): e12721
Published: 02 January 2024
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KVPO4F with excellent structural stability and high operating voltage has been identified as a promising cathode for potassium-ion batteries (PIBs), but limits in sluggish ion transport and severe volume change cause insufficient potassium storage capability. Here, a high-energy and low-strain KVPO4F composite cathode assisted by multifunctional K2C4O4 electrode stabilizer is exquisitely designed. Systematical electrochemical investigations demonstrate that this composite cathode can deliver a remarkable energy density up to 530 Wh kg−1 with 142.7 mAh g−1 of reversible capacity at 25 mA g−1, outstanding rate capability of 70.6 mAh g−1 at 1000 mA g−1, and decent cycling stability. Furthermore, slight volume change (~5%) and increased interfacial stability with thin and even cathode–electrolyte interphase can be observed through in situ and ex situ characterizations, which are attributed to the synergistic effect from in situ potassium compensation and carbon deposition through self-sacrificing K2C4O4 additive. Moreover, potassium-ion full cells manifest significant improvement in energy density and cycling stability. This work demonstrates a positive impact of K2C4O4 additive on the comprehensive electrochemical enhancement, especially the activation of high-voltage plateau capacity and provides an efficient strategy to enlighten the design of other high-voltage cathodes for advanced high-energy batteries.

Research Article Issue
Nano self-assembly of fluorophosphate cathode induced by surface energy evolution towards high-rate and stable sodium-ion batteries
Nano Research 2023, 16(1): 439-448
Published: 31 August 2022
Abstract PDF (13.1 MB) Collect
Downloads:128

In the field of materials science and engineering, controlling over shape and crystal orientation remains a tremendous challenge. Herein, we realize a nano self-assembly morphology adjustment of Na3V2(PO4)2F3 (NVPF) material, based on surface energy evolution by partially replacing V3+ with aliovalent Mn2+. Crystal growth direction and surface energy evolution, main factors in inducing the nano self-assembly of NVPF with different shapes and sizes, are revealed by high-resolution transmission electron microscope combined with density functional theory. Furthermore, NVPF with a two-dimensional nanosheet structure (NVPF-NS) exhibits the best rate capability with 68 mAh·g−1 of specific capacity at an ultrahigh rate of 20 C and cycle stability with 80.7% of capacity retention over 1,000 cycles at 1 C. More significantly, when matched with Se@reduced graphene oxide (rGO) anode, NVPF-NS//Se@rGO sodium-ion full cells display a remarkable long-term stability with a high capacity retention of 93.8% after 500 cycles at 0.5 C and −25 °C. Consequently, experimental and theoretical calculation results manifest that NVPF-NS demonstrates such superior performances, which can be mainly due to its inherent crystal structure and preferential orientation growth of {001} facets. This work will promise insights into developing novel architectural design strategies for high-performance cathode materials in advanced sodium-ion batteries.

Research Article Issue
Constructing Bidirectional Fluorine-Rich Electrode/Electrolyte Interphase Via Solvent Redistribution toward Long-Term Sodium Battery
Energy & Environmental Materials 2023, 6(6)
Published: 04 July 2022
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The high concentration electrolytes with specific solvation structure could passivate the electrodes to prolong battery cycle life but at the expense of increased cost, which limits the wide application in commercialization. The regular concentration (1 M) electrolytes with suitable properties (viscosity, ionic conductivity, etc.) are cost-guaranteed, but undesired reactions would always occur and lead to battery degradation during long cycles. To promote the long-term cycle stability in a cost-effective way, this work constructs bidirectional fluorine-rich electrode/electrolyte interphase (EEI) by redistribution of solvents and electrochemical induction. The fluorinated effect with reasonable zoning planning restricts morphological disintegration, meanwhile, forms spatial confinement on cathode. In particular, the obtained cathode electrolyte interphase (CEI) gets the ample ability of Na+ transport, which benefits from the fluorinated organics arranged in the epitaxy and the hemi-carbonate content acting on the thickness. Thus, the electrochemical long cycling performance of F-NVPOFF-CC full cells is significantly enhanced (the decay rate at 1 C per cycle is as low as 0.01%). Such a fluorine-rich EEI engineering is expected to take transitional layers against the degradation of cells and make ultra-long cycle batteries possible.

Review Issue
Progresses in Sustainable Recycling Technology of Spent Lithium-Ion Batteries
Energy & Environmental Materials 2022, 5(4): 1012-1036
Published: 30 August 2021
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Downloads:10

The number of lithium-ion batteries (LIBs) is steadily increasing in order to meet the ever-growing demand for sustainable energy and a high quality of life for humankind. At the same time, the resulting large number of LIB waste certainly poses safety hazards if it is not properly disposed of and will seriously harm the environment due to its inherent toxicity due to the use of toxic substances. Moreover, the consumption of many scarce precious metal resources is behind the mass production of batteries. In the light of severe environmental, resources, safety and recycling problems, recycling spent LIBs have become an essential urgently needed action to achieve sustainable social development. This review therefore critically analyses the value and the need for recycling of spent LIBs from a variety of resources and the environment. A range of existing technologies for recycling and reusing spent LIBs, such as pretreatment, pyrometallurgy, hydrometallurgy, and direct recycled methods, is subsequently summarized exclusively. In addition, the benefits and problems of the methods described above are analyzed in detail. It also introduces recycling progress of other LIB components, such as anodes, separators, and electrolytes, as well as the high-value cathode. Finally, the prospects for recycling LIBs are addressed in four ways (government, users, battery manufacturers, and recyclers). This review should contribute to the development of the recycling of used LIBs, particularly in support of industrialization and recycling processes.

Research Article Issue
Flexible quasi-solid-state sodium-ion full battery with ultralong cycle life, high energy density and high-rate capability
Nano Research 2022, 15(2): 925-932
Published: 25 June 2021
Abstract PDF (7.3 MB) Collect
Downloads:118

Flexible power sources featuring high-performance, prominent flexibility and raised safety have received mounting attention in the area of wearable electronic devices. However, many great challenges remain to be overcome, notably the design and fabrication of flexible electrodes with excellent electrochemical performance and matching them with safe and reliable electrolytes. Herein, a facile approach for preparing flexible electrodes, which employs carbon cloth derived from commercial cotton cloth as the substrate of cathode and a flexible anode, is proposed and investigated. The promising cathode (NVPOF@FCC) with high conductivity and outstanding flexibility is prepared by efficiently coating Na3V2(PO4)2O2F (NVPOF) on flexible carbon cloth (FCC), which exhibits remarkable electrochemical performance and the significantly improved reaction kinetics. More importantly, a novel flexible quasi-solid-state sodium-ion full battery (QSFB) is feasibly assembled by sandwiching a P(VDF-HFP)-NaClO4 gel-polymer electrolyte film between the advanced NVPOF@FCC cathode and FCC anode. And the QSFBs are further evaluated in flexible pouch cells, which not only demonstrates excellent energy-storage performance in aspect of great cycling stability and high-rate capability, but also impressive flexibility and safety. This work offers a feasible and effective strategy for the design of flexible electrodes, paving the way for the progression of practical and sustainable flexible batteries.

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