Efficient and environmentally friendly separation and recycling of cathode materials and current collectors for lithium-ion batteries by fast Joule heating

Abstract

Spent Li-ion batteries(LIBs) cathodes possess high recycling value. To improve subsequent recovery efficiency and product purity, separating the cathode materials from the aluminum foil is critical. However, traditional separation methods are characterized by high energy consumption, low recycling efficiency, and environmental pollution. This research presents a novel method that involves injecting Joule heat directly into the aluminum foil in the air, resulting in the melting and slight thermal decomposition of the PVDF binder, which reduces its adhesive properties. Owing to the difference in thermal expansion coefficients between the binder and aluminum foil, an instantaneous thermal stress was generated at the interface of the cathode materials and aluminum foil, resulting in a peeling force. This method enabled a rapid and efficient separation of lithium iron phosphate (LFP) and ternary Li-ion (NCM) battery cathode materials. The optimal separation conditions, separation mechanism, and properties of the recovered products were investigated thoroughly using high-speed camera imaging, temperature rise calculations, and microscopic characterization. This chemical-free method avoids the generation of wastewater and gas emissions. Under optimal experimental parameters, the separation efficiency and purity of cathode material reached 99 % and 99.7 %, respectively. Additionally, this method preserves both the structural integrity of the aluminum foil and the crystalline structure of the cathode materials, offering a new pathway for sustainable recycling of end-of-life LIBs.