Recycling the spent cobalt-based perovskites for the high-active oxygen catalysts in zinc-air batteries

Cobalt (Co) is widely used in energy storage and conversion devices, although its content on our planet is not adequate. Therefore, recycling Co from the spent Co-enriched materials is indispensable. Co-based perovskites, which contain abundant Co, are extensively utilized in solid oxide fuel cells, three-way catalysts, and oxygen-permeable membranes, and the recovery of Co from the spent Co-based perovskites is necessary to meet the long-term requirement of Co. In this work, a facile and universal thermal reduction method (750 °C and N2 atmosphere) is employed to convert the spent cobalt-based perovskites into high-performance bifunctional oxygen catalysts for zinc-air batteries (ZABs), achieving high-efficient Co recovery and re-utilization. At high temperatures, melamine and dopamine hydrochloride are transformed into carbon nanotubes, C3N4 and reducing gases (such as NH3 and H2). Simultaneously, the metal elements in the spent Co-based perovskites (SrNb0.1Co0.7Fe0.2O3,SNCF) are converted into nano-scale alloy particles and metal nitrides. Then, the phase structures, micromorphology, and element valences of the obtained multiphase oxygen catalyst (SNCF-Ni-PM) are characterized by X-ray diffraction, scanning/transmission electron microscopy, and X-ray photoelectron spectroscopy, respectively. The electrochemical properties, including oxygen catalytic activities and stability, of SNCF-Ni-PM are measured by linear sweep voltammetry, chronopotentiometry, chronoamperometry, and cyclic voltammetry methods. Considering the practical applications, the aqueous and solid-state ZABs are assembled and measured. The results demonstrate that the multiphase SNCF-Ni-PM mainly includes carbon nanotubes, C3N4 nanosheets, and FeNiN or CoFe nanoparticles. Moreover, SNCF-Ni-PM exhibits excellent bifunctional oxygen catalytic activity, with an oxygen evolution reaction (OER) potential at 10 mA cm-2 of 1.51 V and an oxygen reduction reaction (ORR) half-wave potential of 0.77 V, outperforming most of the reported oxygen catalysts. Using SNCF-Ni-PM, the aqueous and solid-state ZABs can achieve high power densities of 295.9 and 228.4 mW cm-2, respectively, being superior to most ZABs. In addition, the aqueous ZAB with SNCF-Ni-PM can operate stably for 300 hours with a slight degradation. This work provides a feasible method for effectively recycling Co from the spent Co-based perovskites.