From Spent Lithium-ion Battery Cathode to Fuel Cells Atomic-Scale Catalyst

Bridging Li-lon Batteries and Fuel Cells

This invention upcycles end-of-life LiFePO₄-based lithium-ion battery (LIB) cathode into a single-atom electrocatalyst for oxygen reduction reaction (ORR) using a simple partial etching strategy. The LiFePO₄/carbon was converted into Fe single atom-embedded hollow carbon spheres containing minor FeO_x nanoclusters and FePO₄ nanoparticles. The etching strategy breaks a long-standing stereotype by innovatively constructing atomic catalytic sites using a top-down approach. The resulting material exhibits excellent ORR activity/stability in an alkaline medium as demonstrated by the high E_onset of 0.97 V and a slight current decline of 9.5% after 16 hours of testing. Furthermore, a membrane electrode fabricated with this single atom-based catalyst demonstrated great potential value in two practical energy conversion devices: an ammonia fuel cell (FC) and a Zn-air battery (ZAB), building a bridge across energy applications.

(A) Upcycling Process of Spent 18650 LiFePO4 LIBs Cell: Mechanical Dismantling, Physical Separation, Post thermal Treatment, and Partial Etching and (B) Partial Etching Process of the Spent Cathode to Atomic-Scale Catalysts.

Membrane Electrode Fabricated from Single Atom-based Catalyst (left) and Zinc-Air Battery Test Platform (right).

Special Features and Advantages

Environmental protection
LIB waste management
Cross-device LIB upcycling
Cost-effective

Applications

The membrane electrode demonstrates great the potential values in two practical energy conversion devices. It delivers a maximum power density of 51 mW cm−2 in ammonia fuel cell and a peak power density of 185 mW cm−2 in Zn-air battery, much higher than commercial Pd/C or Pt/C catalysts.

Patents

18/455,677 (US)
PCT/CN2023/115011 (PCT)

Principal Investigator

Dr Lawrence Yoon Suk LEE

Department of Applied Biology and Chemical Technology

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