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Article

Sustainable Upcycling of Spent Battery Graphite into High-Performance PEG Anodes via Flash Joule Heating

National Engineering Laboratory for Reducing Emissions from Coal Combustion, Engineering Research Center of Environmental Thermal Technology of Ministry of Education, Shandong Key Laboratory of Green Thermal Power and Carbon Reduction, School of Nuclear Science, Energy and Power Engineering, Shandong University, Jinan 250061, China
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Recycling 2025, 10(5), 171; https://doi.org/10.3390/recycling10050171
Submission received: 22 July 2025 / Revised: 22 August 2025 / Accepted: 28 August 2025 / Published: 2 September 2025
(This article belongs to the Special Issue Lithium-Ion and Next-Generation Batteries Recycling)

Abstract

The upcycling of spent lithium-ion battery graphite constitutes an essential pathway for mitigating manufacturing expenditures and alleviating ecological burdens. This study proposes an integrated strategy to upcycle spent graphite into high-performance porous expanded graphite (PEG) anodes, leveraging flash Joule heating (FJH) as a core technique for efficient decontamination, interlayer expansion, and active etching. Results show that the binders and impurities are efficiently removed by FJH treatment, and the graphite interlayer spacing is expanded. The iron oxide, which acts as an etching reagent, can then be easily intercalated and laid into the decontaminated graphite for subsequent etching. A subsequent FJH treatment simultaneously releases oxidized intercalants and triggers in-situ metal oxide etching, yielding PEG with a rich porous architecture and enhanced specific surface area. This method successfully prepared high-performance porous expanded graphite anode material with a mesoporous structure. The resulting anode delivers a remarkable capacity retention of 419 mAh·g−1 after 600 cycles at 2C, outperforming the performance of commercial graphite anodes. This innovative approach offers a promising route for sustainable graphite reclamation.
Keywords: flash Joule heating; spent graphite; porous expanded graphite; anode; high-value reutilization flash Joule heating; spent graphite; porous expanded graphite; anode; high-value reutilization

Share and Cite

MDPI and ACS Style

Luo, Y.; Sun, J.; Chen, W.; Lu, S.; Wang, Z. Sustainable Upcycling of Spent Battery Graphite into High-Performance PEG Anodes via Flash Joule Heating. Recycling 2025, 10, 171. https://doi.org/10.3390/recycling10050171

AMA Style

Luo Y, Sun J, Chen W, Lu S, Wang Z. Sustainable Upcycling of Spent Battery Graphite into High-Performance PEG Anodes via Flash Joule Heating. Recycling. 2025; 10(5):171. https://doi.org/10.3390/recycling10050171

Chicago/Turabian Style

Luo, Yihan, Jing Sun, Wenxin Chen, Shuo Lu, and Ziliang Wang. 2025. "Sustainable Upcycling of Spent Battery Graphite into High-Performance PEG Anodes via Flash Joule Heating" Recycling 10, no. 5: 171. https://doi.org/10.3390/recycling10050171

APA Style

Luo, Y., Sun, J., Chen, W., Lu, S., & Wang, Z. (2025). Sustainable Upcycling of Spent Battery Graphite into High-Performance PEG Anodes via Flash Joule Heating. Recycling, 10(5), 171. https://doi.org/10.3390/recycling10050171

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