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Cathodes of lithium-ion batteries (LIBs) significantly impact the environmental footprint, cost, and energy performance of the battery-pack. Hence, sustainable production of Li-ion battery cathodes is critically required for ensuring cost-effectiveness, environmental benignity, consumer friendliness, and social justice. Battery chemistry largely determines individual cell performance as well as the battery pack cost and life cycle greenhouse gas emission. Continuous manufacturing platforms improve production efficiency in terms of product yield, quality and cost. Spent-battery recycling ensures the circular economy of critical elements that are required for cathode production. Innovations in fast-charging LIBs are particularly promising for sustainable e-mobility with a reduced carbon footprint. This article provides an overview of these research directions, emphasizing strategies for low-cobalt cathode development, recycling processes, continuous production and improvement in fast-charging capability. 

The intermittent nature of the renewable energy sources drifts research interest towards various electrochemical energy storage devices, such as the lithium ion battery, which offers consistent power supply. The manufacturing cost and electrochemical performance of a battery pack largely depends on the quality of the cathode material, which further depends on the production method and its parameters. However, the traditional stirred tank-based co-precipitation manufacturing process for precursors of lithium nickel manganese cobalt oxide (NCM111) cathode suffers from inhomogeneity in the reaction environment, which leads to non-uniform morphology and particle size distribution (PSD). In this work, slug-flow-based manufacturing platform, which offers a homogeneous reaction environment, is used for the continuous production of NCM111 oxalate precursors. One of the novel features of this work is the comparative study between the quality of batch and slug-flow-derived products. The slug-flow-derived product is found to be better in terms of having bigger particle size, narrower PSD and higher tap density. The study on the single and dual-element precipitation in similar conditions to understand the co-precipitation behavior in the slug-flow manufacturing platform is also a unique feature of this work. Furthermore, the effect of NH4OH concentration and residence time (RT) on the electrochemical performance of cathode were also studied and it is found that the cathode precursors synthesized at a NH4OH concentration of 0.08 M and a RT of 2 minutes followed by lithiation shows a better electrochemical performance of 128 mAh g−1 at 0.1 C with cycling stability of more than 80% both at 0.5 C and 1 C. 

Cost-effective production of low cobalt Li-ion battery (LIB) cathode materials is of great importance to the electric vehicle (EV) industry to achieve a zero-carbon economy. Among the various low cobalt cathodes, Ni-rich lithium nickel cobalt manganese oxide (NCM/NMC)-based layered materials are commonly used in EVs and are attracting more attention of the scientific community due to their high specific capacity and energy density. Various synthesis routes are already established to produce Ni-rich NCM cathodes with uniform particle size distribution and high tap density. Continuous production of highly pure Ni-rich cathode materials with uniformity in inter/intra-particle compositional distribution is critically required. On the other hand, cation mixing, particle cracking, and parasitic side reactions at higher voltage and temperature are some of the primary challenges of working with Ni-rich NCM cathodes. During the past five years, several advanced modification strategies such as coating, doping, core–shell, gradient structure and single crystal growth have been explored to improve the NCM cathode performance in terms of specific capacity, rate-capability and cycling stability. The scientific advancements in the field of Ni-rich NCM cathodes in terms of manufacturing processes, material challenges, modification techniques, and also the future research direction of LIB research are critically reviewed in this article. 

Li−O2 batteries with carbon electrodes made from three commercial carbons and carbon made from waste tea leaves are investigated in this study. The waste tea leaves are recycled from household tea leaves and activated using KOH. The carbon materials have various specific surface areas, and porous structures are characterized by the N2 adsorption/desorption. Vulcan XC 72 carbon shows a higher specific surface area (264.1 m2/g) than the acetylene black (76.5 m2/g) and Super P (60.9 m2/g). The activated tea leaves have an extremely high specific surface area of 2868.4 m2/g. First, we find that the commercial carbons achieve similar discharge capacities of ∼2.50 Ah/g at 0.5 mA/cm2. The micropores in carbon materials result in a high specific surface area but cannot help to achieve higher discharge capacity because it cannot accommodate the solid discharge product (Li2O2). Mixing the acetylene black and the Vulcan XC 72 improves the discharge capacity due to the optimized porous structure. The discharge capacity increases by 42% (from 2.73 ± 0.46 to 3.88 ± 0.22 Ah/g) at 0.5 mA/cm2 when the mass fraction of Vulcan XC 72 changes from 0 to 0.3. Second, the electrode made from activated tea leaves is demonstrated for the first time in Li−O2 batteries. Mixtures of activated tea leaves and acetylene black confirm that mixtures of carbon material with different specific surface areas can increase the discharge capacity. Moreover, carbon made from recycled tea leaves can reduce the cost of the electrode, making electrodes more economically achievable. This study practically enhances the discharge capacity of Li−O2 batteries using mixed carbons and provides a method for fabricating carbon electrodes with lower cost and better environmental friendliness. 

The urea oxidation reaction (UOR) is a possible solution to solve the world’s energy crisis. Fuel cells have been used in the UOR to generate hydrogen with a lower potential compared to water splitting, decreasing the costs of energy production. Urea is abundantly present in agricultural waste and in industrial and human wastewater. Besides generating hydrogen, this reaction provides a pathway to eliminate urea, which is a hazard in the environment and to people’s health. In this study, nanosheets of CuCo2O4 grown on nickel foam were synthesized as an electrocatalyst for urea oxidation to generate hydrogen as a green fuel. The synthesized electrocatalyst was characterized using X-ray diffraction, scanning electron microscopy, and X-ray photoelectron spectroscopy. The electroactivity of CuCo2O4 towards the oxidation of urea in alkaline solution was evaluated using electrochemical measurements. Nanosheets of CuCo2O4 grown on nickel foam required the potential of 1.36 V in 1 M KOH with 0.33 M urea to deliver a current density of 10 mA/cm2. The CuCo2O4 electrode was electrochemically stable for over 15 h of continuous measurements. The high catalytic activities for the hydrogen evolution reaction make the CuCo2O4 electrode a bifunctional catalyst and a promising electroactive material for hydrogen production. The two-electrode electrolyzer demanded a potential of 1.45 V, which was 260 mV less than that for the urea-free counterpart. Our study suggests that the CuCo2O4 electrode can be a promising material as an efficient UOR catalyst for fuel cells to generate hydrogen at a low cost.