Adaptable Eutectic Salt for the Direct Recycling of Highly Degraded Layer Cathodes

Recycling spent lithium-ion batteries (LIBs) is promising for resource reuse and environmental conservation but suffers from complex processing and loss of embedded value of spent LIBs in conventional metallurgy-based recycling routes. Herein, we selected a eutectic LiI-LiOH salt with the lowest eutectic point among binary eutectic lithium salt systems to provide a Li-rich molten environment, not only offering excess lithium but benefiting ion diffusion compared with that in the solid environment. Hence, the highly degraded LiNi0.5Co0.2Mn0.3O2 in spent LIBs which suffers high Li-deficiency and serious structural defects with harmful phase transitions is directly regenerated. A facile one-step heating strategy in the presence of a combination of the eutectic lithium salt and Co2O3 and MnO2 additives not only simplifies the recycling process but also endows the cathode materials with lithium supplementation and structural ordering, which contributes to a restoration of the capacity and stable cycling performance. In particular, this eutectic salt with a low eutectic point helps decrease the temperature and time of the direct recycling process and shows good adaptability for other layer oxide cathode materials (LiCoO2 and LiNi0.6Co0.2Mn0.2O2) in spent LIBs with varying cathode chemistry. As such, the feasibility of the direct recycling route is improved and broadened with simple and efficient processing, providing an idea for energy-saving cathode regeneration in future LIB recycling.