Search Results (212)

The rapid transition toward electrified mobility and climate neutrality has prioritized the structural and environmental optimization of battery electric vehicle (BEV) subsystems. While vehicle lightweighting enhances operational efficiency, the production phase of structural enclosures and battery cells frequently introduces severe environmental and economic impacts and supply chain vulnerabilities. This study presents a comprehensive cradle-to-gate environmental life cycle assessment (LCA), life cycle costing (LCC), and semi-quantitative social assessment of alternative battery housing materials and battery cell architectures. To achieve a functionally accurate comparison, alternative materials, including a novel recyclable thermoplastic acrylic sheet molding compound (SMC), commercial thermoset SMCs, aluminum (AlMg3), and stainless steel, are evaluated using an analytical stiffness- and strength-equivalent methodology across three real-world geometric demonstrators. Simultaneously, lithium iron phosphate (LFP) liquid electrolyte prismatic cells and solid-state polymer pouch cells are assessed. Material-level results indicate that, while aluminum minimizes the structural mass, primary aluminum manufacturing exhibits the highest global warming potential and processing costs. Conversely, Polytec SMC and Elium SMC achieve the lowest environmental impacts alongside competitive total production costs. At the cell level, prismatic LFP architectures display superior environmental performance compared to solid-state pouch cells, which suffer from energy-intensive processing and lower volumetric capacity normalization. Demonstrator-level aggregation reveals that the electrochemical cells heavily dominate the environmental and economic footprint of the complete assembly, with the housing accounting for less than 5% of the total global warming potential (GWP) and 1% of the total costs. The social assessment reveals moderate and comparable performance across all systems, with slight advantages for thermoplastic composite-based configurations in terms of circularity potential and innovation perception. Overall, the study highlights the critical importance of the cell architecture and manufacturing processes in determining battery system sustainability, while demonstrating the relevance of lightweight composite housings in reducing the structural mass with a minimal environmental penalty. Full article

Lithium slag powder (LSP), a by-product of lithium extraction, has attracted increasing interest as a supplementary cementitious material (SCM) due to its aluminosilicate-rich composition and growing availability. However, its limited intrinsic reactivity constrains direct use in cementitious systems. This study systematically investigates the effect of calcination temperature on the physicochemical properties, pozzolanic reactivity, and cement hydration performance of LSP. LSP was thermally treated at 300–900 °C, and structural and morphological changes were characterized using X-ray diffraction, scanning electron microscopy, and Fourier-transform infrared spectroscopy. The reactivity of calcined LSP was quantitatively assessed through isothermal calorimetry (R3 test), thermogravimetric and derivative thermogravimetric analysis. Chapelle testing, leaching tests, and compressive strength measurements of cement mortars. Controlled calcination was found to enhance the intrinsic reactivity and pozzolanic activity of LSP, resulting in improved long-term mechanical performance. The findings provide mechanistic insights and practical guidance for the sustainable use of lithium slag as an SCM in cement-based materials. Full article

The fabrication of efficient Fenton catalysts from solid waste offers a sustainable strategy for achieving waste valorization and wastewater remediation. In this work, after selective separation of valuable Li from spent lithium iron phosphate (LFP), the generated iron-rich slag (IRS) was employed as a Fenton catalyst for the degradation of organic pollutants. IRS catalysts consist of lumpy particles with abundant active sites, enabling efficient H₂O₂ activation. Under optimal conditions, 99.62% of doxorubicin hydrochloride (DOX) can be degraded within 30 min with a rate constant of 0.30 min⁻¹. In the continuous-flow degradation experiment, the catalyst maintains a DOX removal efficiency of over 90% at an effluent volume of 1400 mL. The IRS catalyst exhibits efficient DOX degradation over a wide pH range (2.0–8.0), and it also potentially removes different pollutants, including amodiaquine, tetracycline, methyl orange, and methylene blue. Quenching tests and characterizations reveal the dominant contribution of ·OH radicals as reactive species, while the Fe²⁺/Fe³⁺ cycle facilitates continuous H₂O₂ activation. This work establishes an integrated strategy coupling lithium recovery from spent LFP with catalyst production for advanced wastewater treatment. Full article

Sericin, a silk-derived protein recovered as a by-product of the textile industry, is a renewable biomacromolecule with considerable potential for sustainable material development. Chemical modification represents an effective strategy for its valorization. In this study, acetylation using acetyl chloride (AcCl) was selected as a model reaction to systematically investigate the reactivity of sericin in an N,N-dimethylacetamide/lithium chloride (DMA/LiCl) solvent system and to evaluate the influence of reaction parameters on both the extent of functionalization and protein secondary structure. A Design of Experiments (DoE) strategy, comprising an initial full factorial screening followed by Box–Behnken optimization, was employed to investigate the effects of AcCl equivalents, sericin concentration, and LiCl content. A quantitative FTIR workflow based on constrained Gaussian deconvolution was developed to derive functionalization index (FI) and β-sheet index (BI) from both peak areas and peak intensities, enabling the simultaneous evaluation of chemical modification and structural organization. The exploratory screening identified AcCl as the dominant factor governing sericin functionalization. During the optimization phase, the FI models described the general response trends, whereas the BI was successfully represented by robust quadratic models (R² = 0.977–0.978; adjusted R² = 0.936–0.938), revealing significant linear, interaction, and quadratic effects, with LiCl concentration and sericin concentration playing key roles in governing structural organization. The analytical workflow was verified by reproducibility assessment and independent validation experiments. Overall, this study proposes a quantitative DoE–FTIR framework for systematically investigating sericin functionalization and its associated structural evolution, providing support for future studies aimed at sericin industrial valorization. Full article

Lithium-ion batteries (LIBs) are essential for current technological infrastructure, driving the development of portable electronics, electric vehicles or grid-scale energy storage. The performance and sustainability of LIBs are critically dependent on their anode materials. This comprehensive review analyzes the evolution and characteristics of key anode materials, highlighting the specific properties they confer to the final battery products. Beyond material properties, the synthesis methods employed for these materials, from conventional techniques (such as solid-state reactions, sol–gel, hydrothermal/solvothermal, co-precipitation, etc.) to innovative and greener approaches (like electrospinning and a novel induction furnace-oxidation hybrid method for complex oxides), are a crucial part in the development of sustainable materials. While these methods offer different advantages, the challenges in achieving optimal electrochemical performance, including issues related to material stability, capacity retention and scalability, remain significant for both research and manufacturing industries. Furthermore, a significant focus is placed on strategies for mitigating the environmental impact associated with anode material production, emphasizing the importance of unconventional and sustainable synthesis routes. Ultimately, the sustainable evolution of LIB technology to achieve future energy demands hinges on overcoming existing limitations. This necessitates integrated research combining advanced material modeling and design, scalable and environmentally conscious synthesis techniques and in-depth electrochemical characterization. Full article

This research concentrates on the electric vehicle (EV) industry in China and Japan. China is the largest and Japan the third-largest auto production country after the U.S. This study explores the current and future transition to battery electric vehicles and hybrid electric vehicles in Japan and China. Three Japanese auto companies, Toyota, Honda, and Nissan, and BYD from China are studied in this research. Toyota, Honda, and Nissan are actively pursuing the development of hybrid electric vehicles in Japan. Meanwhile, the research examines the Chinese EV company BYD, which is a major global competitor in the EV industry. This study compares the companies in terms of their strategies, strengths, weaknesses, and export destinations and delineates their competitive strategies and outlooks. In addition, the study examines the elements of the supply chain needed for building EVs, such as lithium, nickel, and cobalt. Furthermore, this research discusses some of the issues with EVs, such as the challenges related to the production and recycling of batteries and the implications as far as green and sustainable practices regarding EVs in the selected countries are concerned. The final part of this research explores how the production of EVs can affect the global reduction of carbon emissions. The findings of this study indicate that the transition to EVs depends on the structural position as far as the supply chain, the manufacturing of electric batteries, charging stations, and the size of the operations are concerned. The results indicate that BYD is in a stronger position in terms of the infrastructure necessary for the production of EVs. Meanwhile, Japanese auto companies are focused on hybrid EVs due to infrastructure related to EV batteries, supply sources, and charging stations. In addition, this research provides informative insights into the future of electric vehicles in the global market. The study offers recommendations for a comprehensive approach that integrates national policies, technological innovation, and the environmental impact of the transition to electric vehicles on a global scale. Full article

In the context of an increasing demand for electricity, batteries increasingly appear as one of the main sources of power supply. In particular, research on batteries is mainly focused on new and high-performance materials, and innovative and more sustainable production processes. This work addresses both aspects by developing a gravure-printed cathode based on lithium nickel manganese cobalt oxide (NMC 111, LiNi_0.33Mn_0.33Co_0.33O₂). To this end, the formulation of a gravure-printable ink was investigated in order to meet both the printing and functional requirements. The formulation of a multicomponent dispersion able to produce a cathodic layer was particularly challenging, since such a system was found to be highly sensitive to the composition and specific interactions among the active material and the other components involved in ink preparation. Although a methodology based on Ca, aimed at obtaining layers with high macroscopic printing quality, was adopted, only a few printable inks having similar characteristics were obtained. From a microscopic point of view, printing allowed the identification of the best ink formulation able to produce the greatest layer homogeneity, thus yielding the best possible performance (150 mAh g⁻¹ at C/20). Full article

The sustainable use of industrial raw materials requires accurate characterization and strategic sourcing. In Portugal, the ceramic sector is economically important and depends heavily on aluminosilicate raw materials such as feldspar, kaolin, and clay. This study evaluates twelve Portuguese samples—four feldspars, four kaolins, and four clays—collected near major ceramic industry hubs in central and northern Portugal. The aim is to assess their suitability for industrial use. The characterization areas included chemical and mineralogical composition, particle size, specific surface area, skeletal density, thermal behaviour, plasticity, colour, and fusibility. The results reveal that feldspars exhibited greater compositional variability, particularly in alkali content, with lithium-bearing samples showing enhanced fluxing behaviour, whereas kaolins and clays presented more homogeneous, kaolinite-rich compositions, consistent thermal behaviour and plasticity suitable for ceramic processing. The proximity of these raw material sources to ceramic production centres reduces transportation costs and environmental impact, supporting sustainable supply chains. Overall, the findings indicate that Portuguese aluminosilicates show properties consistent with ceramic processing requirements, and may serve as local alternatives to imported raw materials, reducing dependence on imports while enhancing the sustainability, resilience, and competitiveness of the national ceramic industry. Future work should focus on the formulation and technological validation in ceramic products. Full article

Silicon suboxide (SiO_x) has been extensively investigated as an anode material for lithium-ion batteries. However, its low electrical conductivity and significant volume expansion during cycling have hindered its practical application. Although compounding SiO_x with carbon can effectively alleviate these issues, practical challenges such as complex preparation processes and high production costs still remain. In this study, porous SiO_x/C anode materials were synthesized in a single step using residue after acid-extraction aluminum from coal fly ash (high silica slag) as the silicon source and calcium carbide as both the reducing agent and carbon source, in a NaCl-CaCl₂ molten salt medium. The intimate interface between SiO_x and carbon not only enhances the electrical conductivity of the electrode but also buffers volume expansion, while the porous structure inside the SiO_x/C particles facilitates rapid ion transport. The SiO_x/C anode fabricated from this material exhibits excellent electrochemical performance and cycling stability: the anode material synthesized at 700 °C for 3 h (denoted as SiO_x/C-700-3) retains a reversible specific capacity of 1093.58 mAh g⁻¹ after 1000 cycles at a current density of 0.4 A g⁻¹. Moreover, the optimized SiO_x/C-700-3 electrode achieves robust long-cycle stability under a high current density of 2 A g⁻¹, sustaining a reversible capacity of 486.22 mAh g⁻¹ after 800 cycles with an average Coulombic efficiency approaching 99.6%. The method proposed in this work provides a new strategy for the preparation of SiO_x/C anode materials and holds great significance for the high-value comprehensive utilization of coal fly ash and the protection of the ecological environment. Full article

Lithium has become a critical resource in the global energy transition; however, its sustainability assessment remains fragmented, as technological performance, environmental impacts, and governance dimensions are typically evaluated independently. This fragmentation constrains the understanding of systemic trade-offs and limits the recognition of sustainability as an emergent property arising from the interaction of technological, hydrogeological, and territorial configurations. This study proposes a systemic approach that conceptualizes lithium extraction technologies as interdependent configurations rather than isolated technical solutions. Based on a structured review of scientific literature and operational evidence, the analysis integrates resource efficiency, technological performance, environmental impacts, and governance dimensions to identify patterns of impact redistribution across water consumption, energy use, production efficiency, and hydrogeological stability. The findings indicate that Direct Lithium Extraction (DLE) should not be interpreted as a universally superior alternative but rather as a reconfiguration of the extraction system that reduces brine withdrawal while increasing dependence on freshwater resources, energy consumption, and uncertainties associated with reinjection processes. Furthermore, evidence from Chile demonstrates that favorable geological conditions do not necessarily translate into sustainability outcomes because of persistent water constraints and socio-environmental tensions. Overall, the sustainability of lithium extraction depends less on the characteristics of individual technologies than on the degree of alignment between technological configuration, hydrogeological conditions, and governance arrangements. These findings shift the focus of assessment from linear comparisons among technologies toward a systemic evaluation of configurations that is better suited to contexts characterized by high socio-hydrogeological complexity. Full article

The recycling of spent lithium-ion batteries and selected complex electronic waste fractions is commonly evaluated using isolated metrics such as leaching yield, metal removal efficiency, and reagent consumption. However, this approach fails to address the central challenge of sustainable valorization: integrating upstream conversion with downstream selective recovery without shifting environmental and separation burdens. This review focuses specifically on spent LIBs as the primary model system, while also drawing insights from related e-waste streams (e.g., printed circuit boards and polymer-containing residues) where the interface-driven framework applies. It examines how key interfaces—solid–fluid, polymer–metal–fluid, membrane–solution, electrode–electrolyte, and crystal–solution—govern metal mobilization, selectivity, effluent quality, product purity, and scalability. Emphasis is placed on hydrothermal and supercritical water processing, PVC/CPVC (Polyvinyl Chloride/Chlorinated Polyvinyl Chloride)-assisted metal mobilization and membrane-based recovery techniques, including nanofiltration, membrane distillation, membrane distillation crystallization, ion exchange, and electrochemical methods. Supercritical water and membrane processes are complementary only when upstream chemistry is designed to facilitate downstream separation. PVC-rich waste is reconsidered as a reactive chlorine source, provided that corrosion, HCl formation, and salt precipitation are controlled. Critical gaps include incomplete mass balances, limited multicomponent studies, weak integration between process stages, and scarce techno-economic and life-cycle analyses. A roadmap is proposed for scalable, integrated hydrothermal–membrane systems enabling efficient resource recovery and water reuse. Full article

Global demand for sustainability drives interest in bioenergy from sustainable feedstock. Agro-industrial waste such as brewer’s spent grains (BSG) is an important by-product of brewing. This study provides a comprehensive review of the current technologies of BSG for energy recovery and BSG-based materials for energy storage applications. The latest scientific progress, not only from conventional processes on anaerobic digestion, combustion, gasification, pyrolysis, torrefaction, and hydrothermal liquefaction but also from several integrated technologies, pretreatment methods, and additives/catalysts regarding the improvement of energy efficiency and process sustainability, was reviewed. In addition, the co-feedstock practices (co-combustion, anaerobic co-digestion, hydrothermal co-liquefaction, anaerobic co-fermentation) and co-production were examined. AD of BSG yields about 302 NL CH₄/kg COD, generating roughly 0.39 kWh of electricity/kg BSG and 1.71 MJ of thermal energy/kg BSG. Ultrasonic pretreatment enhances methane production up to four times (107 L CH₄/kg TVS) and reduces CO₂ emissions by 0.083 t CO₂eq/t BSG. Anaerobic co-digestion of BSG with other brewery waste increased the yield up to 88 mL CH₄/g TVS, generated approx. 0.348 kWh/kg TVS electricity, and reduced emissions by 0.114 kg CO₂eq/kg TVS. Bioethanol yields can reach 72%, while biohydrogen generation was up to 5154 mL H₂/g glucose. BSG pyrolysis provides up to 71.8% bio-oil, and its calorific value is 18–25 MJ/kg. BSG-derived activated biocarbon has a notable surface area (1792 m²/g) for lithium–sulfur batteries. The assessment showed that BSG’s transformation into bioenergy and energy storage materials aligns with waste reduction and sustainable development goals. However, future research on combined alternative wastes, integrated technologies, green nanotechnology, and artificial intelligence technology could lead to optimal performance and facilitate their industrial application. Full article

Achieving the EU’s climate goals by 2050 requires a rapid transition to a resource-efficient and circular economy. The electrification of transport increases the demand for rechargeable lithium-ion batteries (LiBs), where lithium–nickel–cobalt–manganese (Li-NMC) is the predominant cathode technology in the European automotive sector. Large-scale facilities for LiB production and recycling are emerging worldwide, bringing not only technical challenges but also challenges regarding healthy and safe working environments. Current knowledge on occupational exposure and health risks in the LiB industry is limited and largely based on evidence from other occupational settings. However, the LiB industry involves legacy and new combinations of metals and chemicals in novel contexts. Some of these substances have well-known adverse health effects, and combined exposure may increase their absorption and toxicity. Although processes are often highly specialised and automated, manual handling tasks remain, which put workers at risk of exposure. Important knowledge gaps remain regarding exposure levels, exposure pathways, dermal and systemic uptake, combined exposures, and potential health effects among workers. This perspective paper discusses current exposure scenarios and health risks in LiB production and recycling, identifies key knowledge gaps, and highlights future research needs to support evidence-based occupational risk management. To address several of these challenges, the GreenWorkLiB initiative applies a multidisciplinary approach combining exposure assessment, biomonitoring, and occupational medicine. The initiative investigates exposure pathways via air and skin, internal dose through biomonitoring, and potential health effects among workers in LiB production and recycling. The results can support the assessment of human health and safety within the EU’s Safe and Sustainable by Design (SSbD) framework and contribute to safe and sustainable working environments in the LiB industry. Full article

This study presents a novel approach to the use of kraft lignin in electrochemical energy sources, with a focus on its use as anode material. The key novelty of this study is the use of natural casein as an innovative binder in electrode production, offering a sustainable and efficient alternative to conventional binders. The carbonaceous material was obtained from kraft lignin by two heat treatments at a relatively low temperature of 300 °C—one in a nitrogen atmosphere and the other in air. The results indicate that carbonization at this lower temperature provides promising electrochemical properties while improving cost-effectiveness and energy efficiency compared to higher temperature processes. Additionally, wettability analysis based on contact-angle measurements revealed substantially improved electrolyte affinity for casein-based electrodes, which correlates with their enhanced electrochemical performance. The study showed promising performance of the developed electrodes as follows: a capacity of 67 F g⁻¹ for supercapacitor applications, 250 mAh g⁻¹ for lithium-ion batteries, and 50 mAh g⁻¹ for sodium-ion batteries. These results confirm that kraft lignin, in combination with casein as a binder, is an environmentally friendly and economically viable alternative to traditional electrode materials. 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