Cathode active materials using rare metals recovered from waste lithium-ion batteries: A review

Large-scale lithium-ion batteries (LIBs) are overtaking as power sources for electric vehicles and grid-scale energy-storage systems for renewable sources. Accordingly, large amounts of LIBs are expected to be discarded in the near future. Recycling technologies for waste LIBs, particularly for valuable rare metals (Li, Co, and Ni) used in cathode active materials, need to be developed to construct continuous LIB supply chains. Various recovery methodologies, such as pyrometallurgy, hydrometallurgy, and direct recycling, as well as their advantages, disadvantages, and technical features, are briefly introduced. We review the electrochemical performances of these cathode active materials based on recycled rare metals from LIB waste. Moreover, the physicochemical properties and electrochemical performance of the cathode active materials with impurities incorporated during recycling, which have high academic significance, are outlined. In hydrometallurgy-based LIB recycling, the complete removal of impurities in cathode active materials is not realistic for the mass and sustainable production of LIBs; thus, optimal control of the impurity levels is of significance. Meanwhile, the studies on the direct recycling of LIB showed the necessity of almost complete impurity removal and restoration of physicochemical properties in cathode active materials. This review provides a survey of the technological outlook of reusing cathode active materials from waste LIBs. [Display omitted] •Recycling methods for rare metals in waste Li-ion batteries were briefly explained.•Advantages, disadvantages, and outlooks for each recycling technology were outlined.•Influence of impurities in cathode active materials was described.•Future perspectives of impurities for the recovered cathodes were outlined.