Search Results (424)

All-solid-state lithium–sulfur batteries (ASSLSBs) couple the high theoretical energy density of sulfur (2600 Wh kg⁻¹) with the safety and polysulfide-shuttle suppression advantages of solid electrolytes (SEs). In practice, however, sluggish solid-state conversion kinetics, chemo-mechanical degradation in composite cathodes, and large solid–solid interfacial resistance remain the principal barriers to practical implementation. This review systematically examines recent progress across the three key components of ASSLSBs: cathodes, solid electrolytes, and interfaces. For cathodes, S/C composite design strategies and alternative active materials—including Li₂S, metal sulfides, and organosulfur compounds—are discussed. For solid electrolytes, inorganic (sulfide, oxide, halide, and hydride), polymer, and hybrid composite systems are compared. For interfaces, physical strategies (stack pressure, compliant interlayers, three-dimensional cathode architectures) and chemical strategies (cathode–SE and Li metal–SE interphase engineering, in situ stabilization) are evaluated. Outstanding challenges and design guidelines for next-generation ASSLSBs are discussed. Full article

Recovered graphite from spent lithium-ion batteries is an important secondary resource that can reduce reliance on primary graphite and lower the environmental footprint of battery production. In this work, graphite obtained as a carbon-rich residue after industrial hydrometallurgical leaching of NMC111 black mass (2 M H₂SO₄ + 3% H₂O₂) is subjected to three post-leaching washing treatments to assess how far simple, low-intensity steps can further clean the leach residue while preserving the carbon structure. The washing routes are water washing (GW), water washing with ultrasonication (GU) and mild sulfuric-acid washing with 0.1 M H₂SO₄ (GA). ICP-OES and SEM–EDX show that, relative to the leached black mass, all washing treatments reduce residual transition-metal contents by two to three orders of magnitude, and that the mild acid wash provides the lowest bulk metal levels, with several elements at or below detection limits. X-ray diffraction and Raman spectroscopy indicate graphite-dominated patterns and improved structural order, with the ID/IG ratio decreasing from 0.62 (GW) to 0.11 (GA) and the corresponding in-plane crystallite size increasing from 30.6 nm to 168 nm. Overall, the mild acid washing step is the most effective low-impact post-leaching purification route, yielding a thoroughly cleaned low-metal graphite fraction that preserves the graphite framework and constitutes a suitable intermediate for further upgrading or reuse in secondary applications. Full article

The potassium-rich mother liquor generated from the sulfuric acid process for lithium extraction from spodumene cannot be directly used for the production of battery-grade lithium salts, resulting in lithium resource loss. To address the issues of slow reaction rate and high seed crystal dosage in the traditional jarosite process for potassium removal, this paper systematically optimizes the type, dosage, and particle size of seed crystals based on the mechanisms of crystal nucleation and growth, ion occupancy competition, and interfacial crystallization-driven behavior. Results show that potassium jarosite seed offers high crystallographic compatibility, ease of preparation, and the best overall performance. Seed particle size must balance specific surface area and dispersibility; either too large or too small is detrimental to uniform crystal growth. Thermodynamic and kinetic analyses confirm that jarosite precipitation is strongly spontaneous and chemically controlled. Under the optimal process conditions (pH = 1.5, n(Fe³⁺)/n(K⁺) = 3.5:1, 1 g of potassium jarosite seed, 95 °C, 1 h), the potassium removal rate reaches (92.60 ± 0.48)%, and the lithium recovery rate is (95.20 ± 0.34)%. Lithium loss mainly arises from precipitate entrainment and insufficient washing; enhanced washing can further improve recovery. This study elucidates seed-mediated crystallization regulation and provides both theoretical guidance and technical reference for efficient potassium removal and high-value lithium recovery from potassium-rich mother liquor. Full article

Spent lithium-ion battery electrolytes contain fluorine-, sulfur-, and phosphorus-bearing toxins, necessitating deep detoxification and directional conversion into C₁–C₆ light hydrocarbons. To elucidate the specific catalytic roles and sequential activation of cathode metals (Li, Ni, Co, Mn), this work systematically deconvolutes their mono- and multi-metallic migration mechanisms over a CaO-ZSM-5* catalyst during vacuum catalytic pyrolysis (530 °C, 100 Pa). Results reveal that Li⁺ and Ni²⁺ dominate C–O bond cleavage in carbonates and CaO-ZSM-5*-assisted decarboxylation and oxygen fixation, significantly increasing the relative hydrocarbon content. Conversely, Co^2/3+ and Mn⁴⁺ release reactive oxygen species, causing deep oxidation of hydrocarbons into CO₂ and antagonizing the targeted conversion. In multi-metallic systems, forming composite metal oxides (M_xN_yO_z) increases the energy barrier for releasing active catalytic ions, hindering carbonate cleavage and leaving unreacted carbonate feedstocks. For detoxification, F and P are effectively immobilized as CaF₂ and Ca₂P₂O₇. The relative content of detected gas-phase nitriles is minimized to <2% due to the strong antagonistic effect of Ni²⁺ on Li⁺-promoted hexanedinitrile cleavage, while sulfur species derived from 1,3-propane sultone are converted to SO₂ and ultimately mineralized as calcium and metal-sulfur salts. Mechanistically, product distributions and crystallographic properties suggest a hypothesized sequential activation model—Li⁺ → Ni²⁺ → Mn⁴⁺—governing reactivity, whereas Co^2/3+ does not participate in the synergistic detoxification and selective upgrading process. This migration–reaction coupling framework provides critical insights for cathode-assisted in situ catalytic pyrolysis and closed-loop electrolyte recycling. Full article

The need for the rapid advancement of lithium-based energy storage technologies continues to outpace progress in materials development and manufacturing, creating a widening gap between laboratory-scale innovation and industrial deployment. There is a need to examine the key materials and processing challenges that limit the performance, cost-effectiveness, and sustainability of next-generation lithium batteries. For material considerations, many commonly used electrodes face issues of volumetric expansion and performance degradation over charging cycles. To address these issues, binders are a crucial component to consider as they adhere active materials to the electrodes, and their structure can be altered to mitigate undesirable effects from these components. Hence, the selection and exploration of alternative binders are becoming increasingly important in the pursuit of longer-lasting and safer Li-batteries. From a manufacturing perspective, current production lines rely on multistep, energy-intensive processes, e.g., from slurry-mixing to cell assembly, that elevate costs and complicate scale-up. Emerging chemistries incorporating nanomaterials or solid-state components face additional barriers related to yield, process control, and defect management, all of which can exacerbate safety risks related to processing during production and thermal runaway in produced batteries. End-of-life considerations, including disassembly, recycling, and the safe handling of toxic materials, further contribute to the technological and logistical complexity of large-scale deployment. The field is moving toward sustainable material alternatives, more efficient and adaptive manufacturing routes, and advanced technologies such as solid-state electrolytes and nanostructured electrodes. Together, these developments provide a roadmap for overcoming current bottlenecks and enabling the next generation of high-performance, safe, and sustainable lithium battery technologies. This review examines the progress made in finding alternative materials and synthesis methods for the optimization of lithium battery cells, with a focus on the development of novel binders, slurry synthesis and manufacturing framework. In addition, the advantages and limitations of the alternative binder materials and processes are also explored, with a focus on scalability for manufacturing, safety concerns, sustainability and end-of-life challenges. Full article

Lithium–sulfur (Li–S) batteries hold great promise for next-generation energy storage owing to their ultrahigh theoretical energy density; however, their practical application is severely hampered by the polysulfide shuttle effect and the penetration of lithium dendrites through the separator. In this work, a carboxyl-containing anionic polymer (TPU-DMBA) is synthesized and composited with Ketjen Black (KB), and the resulting mixture is coated onto a commercial polypropylene separator via a simple doctor-blade method. In this design, the porous KB network provides physical adsorption to capture polysulfides, while the dissociated carboxylate groups (–COO⁻) generate strong electrostatic repulsion against negatively charged polysulfide anions (S_n²⁻). This dual-mechanism strategy—adding electrostatic repulsion on the basis of physical adsorption—effectively suppresses the shuttle effect. In addition, the flexible polymer backbone increases the tensile strength of the separator by approximately 30%, enhancing its resistance against dendrite penetration. The carbon material also significantly improves electrolyte wettability (the contact angle decreases from 41.6° to 11.7°) and ionic conductivity (from 0.48 × 10⁻³ to 0.88 × 10⁻³ S cm⁻¹). The polymer itself acts as a binder, eliminating the need for additional binder addition. Benefiting from the synergy of electrostatic repulsion, physical adsorption, and mechanical reinforcement, the prepared modified separator endows the Li–S battery with an initial specific discharge capacity of 1373.15 mAh g⁻¹ at 0.1 C and an initial discharge capacity of 714.46 mAh g⁻¹ at a high rate of 2 C. After 200 cycles at 2 C, the capacity remains 577.93 mAh g⁻¹, with a capacity retention of 80.89%. This work provides a low-cost, scalable, and binder-free separator modification strategy that simultaneously suppresses the polysulfide shuttle and resists dendrite growth, opening a new and effective pathway toward practical high-performance Li–S batteries. Full article

Preceramic polymers, especially silicon oxycarbide (SiOC) and silicon carbonitride (SiCN) ceramics, have gained significant attention due to their wide range of applications in many fields, particularly in energy storage devices beyond conventional lithium-ion batteries (LIBs). This review focuses on the synthesis, structural characteristics, and properties of SiOC and SiCN ceramics as electrodes for battery applications. Furthermore, their promising applications as electrode materials for energy storage systems are explored, along with the most recent advances in the development of such materials and their use in lithium-ion batteries (LIBs), lithium-sulfur batteries (LSBs), potassium-ion batteries (PIBs), sodium-ion batteries (SIBs), and supercapacitors. This review addresses the distinct advantages of SiOC and SiCN ceramics, including high thermal stability, mechanical robustness, and adaptable microstructures. It also examines the challenges associated with the commercialization of these ceramics, including issues related to electronic conductivity and ion transport pathways. Full article

The demand for flexible and wearable electronics has intensified the need for conformable, high-performance, and self-sustaining power sources. Flexible supercapacitors (FSCs) and flexible batteries (e.g., lithium-ion and lithium–sulfur) are promising owing to their high-power density, long cycle life, and mechanical flexibility. A transformative solution lies in integrating these storage devices with mechanical energy harvesters, particularly triboelectric nanogenerators (TENGs), to create autonomous self-charging power systems (SCPSs). TENGs exhibit high output, versatile operational modes, material flexibility, and efficient energy harvesting from body movements. This review provides an overview of the recent advances in flexible energy storage technologies, encompassing carbon-based materials, MXenes, polymers, metal oxides, metal–organic frameworks (MOFs), and their hybrid architectures. It discusses the synergistic integration of these storage devices with TENGs to realize multifunctional SCPSs. It also highlights the fundamental design principles of flexible devices, the critical interplay of materials and architecture, and the journey towards monolithic system integration. The review also underscores the importance of managing harvesters’ pulsed output for efficient storage. Finally, a critical analysis of the challenges, including the energy density–flexibility compromise, environmental stability, and safety, is presented, alongside a forward-looking perspective on commercialization pathways for these technologies to power the next generation of autonomous wearable and sustainable electronic systems. Full article

Hybrid-electric propulsion and alternative energy carriers are being considered to mitigate the climate impact of short-range regional aviation. Within this framework, the HERA (Hybrid Electric Regional Architecture) project investigates advanced propulsion architectures for a next-generation 72 passenger regional platform. This work presents a cradle-to-grave Life Cycle Assessment of two HERA reference configurations and compares them with a conventional 70 passenger turboprop representative of current service aircraft. The analysis focuses on lithium–sulphur batteries, proton exchange membrane fuel cells, liquid hydrogen storage tanks, and electric motors. The assessment is implemented through a parametric LCA tool supported by a detailed Life Cycle Inventory based on Ecoinvent v3.8 and evaluated using ReCiPe 2016 midpoint indicators. The system boundary includes raw material extraction, manufacturing and assembly, operation under defined mission profiles, maintenance with component replacement, and End-of-Life (EoL) treatment. Results show that the operational phase remains the main driver of climate change impacts, exceeding 95% of total CO₂ equivalent emissions across configurations. The battery-based hybrid reduces fuel consumption but increases manufacturing and maintenance burdens. The fuel cell configuration shows a more balanced life cycle profile, with platinum identified as a critical hotspot. Full article

Lithium–sulfur batteries (LSBs) offer a theoretical energy density of 2600 Wh kg⁻¹ but suffer from the polysulfide shuttle effect, which causes rapid capacity decay and limits practical application. To address this, we developed a bifunctional separator coating using Ni-doped α-MnO₂ combined with carbon nanotubes (Ni-MnO₂/CNTs). Ni doping induces lattice expansion due to the larger Ni²⁺ ionic radius, modulating the electronic structure to create more active sites, enhance electrical conductivity, and improve polysulfide adsorption and redox kinetics. The needle-like morphology further strengthens physical/chemical confinement of polysulfides and accelerates conversion reactions. Batteries with the Ni-MnO₂/CNTs-modified separator deliver a high-rate capacity of 813 mAh g⁻¹ at 5 C and exhibit a low capacity decay rate of 0.0399% per cycle over 1500 cycles at 2 C. Even under high sulfur loading (∼10 mg cm⁻²) and lean electrolyte conditions (10 μL mg⁻¹), the cell maintains stable cycling with a decay rate of 0.0929% per cycle over 300 cycles at 0.2 C. This lattice-modulation strategy on commercial separators provides a simple, effective pathway toward high-energy-density, long-life LSBs. Full article

Lithium sulfide (Li₂S) is indispensable for lithium–sulfur batteries and sulfide solid-state batteries. However, its high preparation cost and strict process conditions represent core bottlenecks restricting large-scale commercial application. To address this issue, a novel process featuring a low-cost, high-safety, and controllable reaction is proposed in this work. Compared with the commercial H₂S-based route for Li₂S production, the developed process presents distinct advantages, including accessible raw materials, high safety, low overall cost, and low environmental load. Using Li₂SO₄·H₂O as the raw material and Ti as the reducing agent, high-purity T-Li₂S (>99.9%) is successfully synthesized via solid-state sintering and purification, yielding a higher purity level than that of commercial C-Li₂S (>99.7%). Furthermore, sulfide all-solid-state electrolytes T-Li_5.3PS_4.3ClBr_0.7 and C-Li_5.3PS_4.3ClBr_0.7 are prepared using the as-obtained T-Li₂S and commercial C-Li₂S as precursors, respectively. The room-temperature Li-ion conductivities are determined to be 14.5 mS/cm and 11.0 mS/cm, revealing faster ion migration and efficient ion transport in T-Li_5.3PS_4.3ClBr_0.7 without high-temperature assistance, which fully validates the feasibility of the proposed strategy. Overall, this work provides a new technical route for the preparation of high-purity Li₂S, showing promising application prospects. Full article

LaFeO₃ nanofibers and Ag-doped LaFeO₃ nanofibers were fabricated via an approach combining electrospinning with calcination. Their crystal structures, micro-morphologies, and chemical compositions were determined by X-ray diffraction, scanning electron microscopy, transmission electron microscopy, X-ray photoelectron spectroscopy, Raman spectroscopy, and Fourier-transform infrared spectroscopy. In addition, the conduction mechanisms and magnetic properties of the two samples were investigated using a semiconductor analyzer and a vibrating sample magnetometer. Rietveld refined X-ray diffraction analyses confirmed the orthorhombic structure. The two samples showed a nanofibrous structure. For Ag-doped LaFeO₃, the conduction was dominated by the ohmic conduction mechanism in a low-resistance state, while it was governed by space-charge-limited current conduction in a high-resistance state. It also showed a high on/off ratio of 3.6 × 10³. The coercivity and remanence values of Ag-doped LaFeO₃ were 200 Oe and 0.000404 emu g⁻¹. This, thus, indicates the considerable application potential of Ag-doped LaFeO₃ for resistive random-access memory devices and magnetoresistive random-access memory devices. Full article

Lithium–sulfur (Li-S) battery technology has attracted significant research interest owing to sulfur’s remarkable theoretical capacity and exceptional energy density potential. Nevertheless, the low conductivity of sulfur and the “shuttle effect” pose challenges to its practical applications. To enhance electrochemical performance, this work developed nitrogen-doped graphene (NG) nanosheets as a separator coating for Li-S battery. As a modification layer for separators, NG acts as a physical barrier that prevents polysulfides from migrating across the separator to reach the anode, thereby mitigating the shuttle effect. Additionally, NG improves the conductivity of the separator and enhances wettability between the separator and electrolyte, facilitating uniform transmission of lithium ions. Notably, NG functionalized separators demonstrate excellent mechanical flexibility, contributing to improved cycle stability for batteries. Furthermore, theoretical calculations indicate a strong interaction between NG and lithium polysulfides (LiPSs), effectively inhibiting polysulfide migration. The Li-S battery utilizing the NG modified separator maintains a capacity retention rate of 51.5% after 100 cycles at 0.1 C with a sulfur loading of 1.47 mg/cm² and exhibits a capacity decay rate of only 0.092% after 500 cycles at a discharge rate of 1 C. This work highlights the potential advantages of employing NG as a separator coating layer in enhancing the electrochemical performance of the Li-S battery. Full article

Lithium–sulfur (Li–S) batteries have emerged as a promising next-generation energy storage solution as the capacity demands on lithium-ion systems begin to exceed practical limits. In a global push for renewable energy and sustainable practices, Li–S technology offers several compelling advantages. Both lithium and sulfur are relatively inexpensive (especially compared to the transition metals used in lithium-ion cells), and Li–S batteries are easier and less costly to recycle. Moreover, Li–S chemistry carries a theoretical energy density about five times greater than that of current lithium-ion batteries, making it attractive for high-energy-density applications. Because of these advantages, research interest in Li–S batteries remains high despite significant challenges that still limit their performance and lifespan. However, despite these advantages, several fundamental challenges limit the practical deployment of Li–S batteries, including the polysulfide shuttle effect, large volume expansion of sulfur during cycling, low intrinsic electrical conductivity of sulfur and its discharge products, and instability of the lithium metal anode caused by dendrite formation. This paper explains the working principles of Li–S batteries, analyzes the key challenges and recent achievements in their development, and surveys various mechanical engineering applications for which Li–S batteries are being explored, as well as prospects for their future commercialization and sustainability. Full article

Lithium–sulfur (Li-S) batteries hold great promise for next-generation energy storage, offering high theoretical energy density and cost-effectiveness. However, challenges like sulfur’s low conductivity, polysulfide dissolution, and significant volume changes limit their practical application. This study addresses these issues by investigating porosity-engineered carbon hosts, specifically potassium hydroxide (KOH)-activated Black Pearl carbons (BP2000, BP1300, and BP800). Varying KOH-to-carbon ratios allowed precise tailoring of micro- and mesoporous structures, optimizing sulfur loading, electrolyte infiltration, and ion transport. Composites were characterized by TGA, NLDFT, SEM, XRD, and FTIR and electrochemically (cycling, CV, EIS). The KOH-modified BP2000 1:1 cathode, exhibiting the highest mesopore volume increase, demonstrated superior electrochemical performance, including enhanced cycling stability, rate capability, and reduced charge-transfer resistance. These findings emphasize the importance of optimizing pore distribution in carbon hosts for high-performance Li-S batteries and provide valuable insights for advanced energy storage material design. Full article