Journal of the Chinese Ceramic Society, Volume. 53, Issue 8, 2166(2025)
Ultra-Fast and Precise Regeneration of Electrode Materials from Spent Lithium-Ion Batteries
The pursuit of carbon neutrality has become one of global priorities, requiring the widespread adoption of electrification technologies across various sectors, including transportation, industrial processes, and residential applications. A critical factor in this transition is the integration of distributed energy systems that harness renewable energy sources, such as solar, wind, and hydroelectric power. These intermittent energy sources necessitate advanced energy storage systems to ensure a continuous and efficient energy supply. Among the various energy storage technologies under investigation, lithium-ion batteries (LIBs) have emerged as the most widely applied due to their high energy density, long cycle life, and scalability. However, the rapid growth in LIB ownership and demand has led to concerns about resource scarcity and the environmental pollution caused by spent batteries. Traditional recycling methods, such as pyrometallurgy and hydrometallurgy, although mature and widely used, suffer from several disadvantages, including high energy consumption, substantial pollution, lengthy processing times, and high costs. These limitations make them unsuitable for meeting the modern industry's demands for efficiency, economic viability, and environmental sustainability. Therefore, there is an urgent need to develop rapid, efficient, and environmentally friendly direct repair methods for battery materials.This review begins by examining the failure mechanisms of electrode materials and extends to the current advancements in electrode material repair methods. The failure mechanisms can be broadly categorized into active material degradation and interface reaction failures. Cathode materials, due to their higher recovery value, have attracted significant attention and research. The main recovery methods for cathode materials include solid-state sintering regeneration (SSR), hydrothermal regeneration (HTR), electrochemical regeneration (ECR), eutectic salt regeneration (ESR), and chemical lithiation regeneration (CLR). Among these, solid-state sintering and hydrothermal regeneration are the most technologically mature, with the highest industrial potential. However, both methods still require prolonged high-energy input, raising concerns regarding their economic and environmental sustainability. On the other hand, anode material recycling, driven more by the need to extract valuable metals than by economic incentives, primarily focuses on upgrading waste materials.Compared to traditional synthesis techniques, which suffer from high energy consumption and inefficiency, ultra-fast synthesis technology can instantaneously release large amounts of energy to quickly initiate chemical reactions. After the reaction is completed, energy input can be rapidly withdrawn to facilitate efficient cooling. This technology has attracted increasing attention in the materials synthesis field due to its efficiency and low energy consumption. The review then summarizes representative methods, including Joule heating, laser-assisted techniques, and microwave-assisted techniques, discussing their advantages, disadvantages, and applicability. It also analyzes the thermodynamic and kinetic differences between ultra-fast and traditional synthesis methods, emphasizing how ultra-fast synthesis breaks through conventional limitations by combining ultra-high temperatures with instantaneous reaction times. This approach provides new pathways for the novel synthesis of advanced functional materials, such as energy materials, high-performance catalysts and high-strength metal materials.Ultra-fast synthesis, with its low energy consumption and high efficiency, is rapidly becoming a critical breakthrough in the field of electrode material repair and regeneration. This review comprehensively outlines recent advancements in ultra-fast synthesis for both cathode and anode materials. Ultra-fast synthesis has successfully facilitated the regeneration of electrode materials such as LiCoO2 (LCO), LiFePO4 (LFP), LiNixCoyMn1-x-yO2 (NCM), graphite anodes, and silicon-based anodes. Despite the promising progress, challenges remain in scaling up ultra-fast synthesis for industrial applications. Precise control over energy input and product quality uniformity is crucial for industrial implementation. Moreover, the adaptation of ultra-fast synthesis to various material systems and a deeper understanding of the reaction mechanisms are ongoing research topics. The rapid development of artificial intelligence (AI) offers new opportunities for integrating AI into ultra-fast synthesis, enabling better process optimization and outcome prediction. In conclusion, ultra-fast synthesis represents a revolutionary approach in battery material repair and regeneration, offering a promising alternative to traditional recycling methods and supporting the transition towards a more sustainable energy future.Summary and prospectsThis review comprehensively summarizes the development background, application progress, and challenges faced in the recycling and repair of battery materials, with a focus on ultra-fast synthesis technology. Compared to traditional methods, ultra-fast synthesis has made significant advancements in the field of battery materials due to its speed, efficiency, and environmental sustainability. It has increasingly become the focal point of research. Meanwhile, the rapid development of artificial intelligence technology has provided strong support for deepening the understanding of the mechanisms behind ultra-fast synthesis, guiding its research direction, and improving its adaptability for industrial applications. Looking ahead, with the continued advancement of green low-carbon technologies and the growing demand for efficient recycling techniques, ultra-fast synthesis is expected to play a crucial role in promoting the recycling and utilization of battery materials, driving industrial upgrades, and providing key momentum for the sustainable development of the new energy industry through continuous innovation and optimization.
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LIU Hang, LI Boyue, HU Xueshan, ZOU Zhi, WAN Jiayu. Ultra-Fast and Precise Regeneration of Electrode Materials from Spent Lithium-Ion Batteries[J]. Journal of the Chinese Ceramic Society, 2025, 53(8): 2166
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Received: Dec. 25, 2024
Accepted: Sep. 5, 2025
Published Online: Sep. 5, 2025
The Author Email: WAN Jiayu (wanjy@sjtu.edu.cn)