Upcycling electrode materials from spent single-use zinc‑carbon/alkaline batteries into rechargeable lithium-ion battery application

Abstract

Battery recycling/upcycling is a key component of modern e-waste reduction by transforming discarded electrode powder to value-added materials and chemical feedstocks for the proposed applications. In this study, electrode powder from spent zinc‑carbon/alkaline batteries was upcycled into LiMn2O4 cathode and carbon anode for rechargeable lithium-ion battery. The main metallic contents (zinc and manganese) in electrode powder were quantitatively leached using diluted H2SO4 with the presence of H2O2 as a reducing agent. By applying sequential precipitation, ZnS nanospheres and MnCO3 nanocubes were obtained as determined by X-ray diffraction (XRD) and scanning electron microscopy (SEM). The recovered MnCO3 was heated with a stoichiometric amount of Li2CO3 to produce high crystalline and pure LiMn2O4. For the electrochemical performance, the results show that upcycled LiMn2O4 exhibits initial discharge capacity of 99.0 mAh g−1 for zc-LiMn2O4 and 111.0 mAh g−1 for al-LiMn2O4, compared to 90.4 mAh g−1 for pristine LiMn2O4. Moreover, recovered carbon materials obtained as an insoluble powder after acid leaching possess unique morphology and crystallinity. The zc‑carbon shows superior cycling performance with reversible charge capacity of 552 mAh g−1 at 1C rate after 100 cycles. This study provides the great potential for upcycling waste battery electrodes to high-value LiMn2O4 cathode and carbon anode for lithium-ion battery application.