Dual-function surface–bulk engineering via a one-step strategy enables efficient upcycling of degraded NCM523 cathodes†
Abstract
Enhancing the performance of recycled cathodes and improving their market competitiveness against comparable commercial cathode materials remains a fundamental challenge for direct recycling technologies of spent cathodes. Herein, a dual modification strategy incorporating surface coating and bulk doping of cathode materials during the regeneration process of spent cathodes has been implemented to enhance the cycling stability. The composite coating layer consisting of Li2SO4, Li3N, LiNO3, and LiF on the surface of regenerated cathodes facilitates Li+ transport and mitigates electrolyte-induced cathode material degradation. F doping facilitates the formation of F–Ni bonds, which effectively suppresses the oxidation of Ni2+ to Ni3+, thereby enhancing the regeneration efficiency of spent cathodes while reducing the formation of detrimental spinel and rock-salt phases. N doping generates strong N–O bonds that effectively immobilize lattice oxygen, thereby stabilizing the crystal structure. The upcycled cathode demonstrates superior electrochemical performance, achieving a discharge specific capacity of 168.8 mAh g−1 at 0.1C and the capacity retention is 77.1% after 200 cycles at 0.5C. This study holds significant importance for upcycling spent cathodes into fully healthy cathodes with long-life characteristics.