Spent Lithium Manganese Oxide cathodes as precursors for high-voltage spinel cathode materials and high-capacity layered Li-/Mn-rich cathodes

Video Engineering 2025 Graduate Exhibition

Presentation by Samukeliso Dube

Exhibition Number 531

Abstract

The growing demand for lithium-ion batteries, coupled with environmental and economic challenges of virgin mineral extraction and managing low-cost spent batteries, underscores the need for efficient and sustainable recycling processes. Most recycling efforts focus on cathode materials of high economic value such as lithium cobalt oxide (LCO) and lithium nickel manganese cobalt oxide (NMC). Despite its perceived low economic value, the spent lithium manganese oxide (LMO) battery stream holds a significant market share, making it necessary to find viable technological solutions for recovering materials from this waste stream. Conventional hydrometallurgical and pyrometallurgical approaches to produce final or precursor materials are the primary methods of recycling secondary batteries. This project takes a different approach, by focusing on the upcycling of lithium manganese oxide (LMO) batteries through nanostructuring and doping with various transition metals like Ni, Co and Ce. Both nanostructuring, and doping are established methods in the material sciences. In battery recycling, these methods have been applied in relithiation processes, while doping has been applied to virgin LMO to improve performance. This project leverages established insights from these areas of research to develop a feasible, cost-effective, and green process for spent LMO upcycling. Phase analysis using XRD revealed that the cubic crystal structure of the LMO is preserved after doping with nickel and cobalt. SEM analysis shows that the ceria nanoparticles are well dispersed on the surface of the LMO.

Importance

This research is crucial for ensuring resource sustainability and reducing the environmental impact of waste batteries. As the demand for critical minerals continues to grow in energy systems, developing innovative, cost-effective and energy efficient recycling technologies is imperative to reduce the dependence on virgin materials and extend the life-cycle of the critical minerals. Through adopting advanced recycling techniques such as upcycling through nanostructuraing and transition metal doping, the stability of the LMO cathode materials can be significantly enhanced. In addition, this project will increase awareness of the importance of recycling, as I have designed informative flyers and distributed them in various departments around the University Park Campus at Penn State University.