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At least 289 records · Page 16

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DOE OSTI2012

Radiotoxicity Characterization of Multi-Recycled Thorium Fuel - 12394

As described in companion papers, Westinghouse is proposing the implementation of a thorium based fuel cycle to burn the transuranic (TRU) contained in the used nuclear fuel. The potential of thorium as a TRU burner is described in another paper presented at this conference. This paper analyzes the long-term impact of thorium on the front-end and backend of the fuel cycle. This is accomplished by an assessment of the isotopic make-up of Th in a closed cycle and its impact on representative metrics, such as radiotoxicity, decay heat and gamma heat. The behavior in both thermal and fast neutron energy ranges has been investigated. Irradiation in a Th fuel PWR has been assumed as representative of the thermal range, while a Th fuel fast reactor (FR) has been employed to characterize the behavior in the high-energy range. A comparison with a U-fuel closed-cycle FR has been undertaken in an attempt of a more comprehensive evaluation of each cycle's long-term potential. As the Th fuel undergoes multiple cycles of irradiation, the isotopic composition of the recycled fuel changes. Minor Th isotopes are produced; U-232 and Pa-231 build up; the U vector gradually shifts towards increasing amounts of U-234, U-235 etc., eventually leading to the production of non negligible amounts of TRU isotopes, especially Pu-238. The impact of the recycled fuel isotopic makeup on the in-core behavior is mild, and for some aspects beneficial, i.e. the reactivity swing during irradiation is reduced as the fertile characteristics of the fuel increase. On the other hand, the front and the back-end of the fuel cycle are negatively affected due to the presence of Th-228 and U-232 and the build-up of higher actinides (Pu-238 etc.). The presence of U-232 can also be seen as advantageous as it represents an obstacle to potential proliferators. Notwithstanding the increase in the short-term radiotoxicity and decay heat in the multi-recycled fuel, the Th closed cycle has some potentially substantial advantages compared to the U cycle, such as the smaller actinide radiotoxicity and decay heat for up to 25,000 years after irradiation. In order for these benefits to materialize, the capability to reprocess and remotely manufacture industrial amounts of recycled fuel appears to be the key. Westinghouse is proposing the implementation of a thorium based fuel cycle to burn the TRU contained in the current UNF. The general approach and the potential of thorium as TRU burner is described in other papers presented at this conference. The focus of this paper is to analyze the long-term potential of thorium, once the legacy TRU has been exhausted and the thorium reactor system will become self-sufficient. Therefore, a comparison of Th closed cycle, in fast and thermal neutron energy ranges, vs. U closed cycle, in the fast energy range, has been undertaken. The results presented focus on selected backend and front-end metrics: isotopic actinide composition and potential implications on ingested radiotoxicity, decay heat and gamma heat. The evaluation confirms potential substantial improvements in the backend of the fuel cycle by transitioning to a thorium closed cycle. These benefits are the result of a much lower TRU content, in particular Pu-241, Am-241 and Pu-240, characterizing the Th vs. U actinide inventories, and the ensuing process waste to be disposed. On the other hand, the larger gamma activity of Th recycled fuel, consisting predominantly of hard gammas from U-232's decay products, is a significant challenge for fuel handling, transportation and manufacturing but can be claimed as beneficial for the proliferation resistance of the fuel. It is worth remembering that in our perspective the Th closed cycle and the U closed cycle will follow a transmutation phase which will likely take place over several decades and dictate the technologies required. These will likely include remote fuel manufacturing, regardless of the specific system adopted for the transmutation, which could then be inherited for the ensuing closed cycles. Finally, specific data related to the fuel manufacturing and separation technologies and their performance in the prospected industrial scale deployment, are key for further quantification of the potential merits of the options explored. Further studies in this direction should be warranted before making definitive conclusion. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Near-Complete Retention of Technetium During Vitrification of Hanford Low Activity Waste With Recycle - 17315

Technetium is one of the more volatile radionuclides for which retention in low activity waste (LAW) glass under the high temperature conditions during vitrification can vary depending on feed composition, feed chemistry, and melter operating parameters. High retention of technetium in the glass is desirable in order to minimize the fraction of technetium that is directed to secondary waste streams, which include liquid off-gas treatment system effluents. Consequently, test data are crucial to assess and underpin the assumptions underlying such mass balance projections, the compositions of secondary waste streams, and, in particular, the effects of recycle on increasing the incorporation of technetium in the glass products and minimizing the fraction in non-glass waste forms. Previous testing performed on a scaled melter system that incorporates prototypical off-gas treatment components and real-time recycle of the liquid effluents back to the melter feed demonstrated that recycle resulted in significant increases of the incorporation of technetium into the LAW glass product and behavior that was in good agreement with process models for the system. However, the maximum technetium retention achieved in those tests was less than predicted. Tests conducted in the present work demonstrated, for the first time, near-complete retention of technetium in the LAW glass product with recycle. Holdup of technetium in the vacuum evaporator, which concentrates the liquid effluents prior to their recycle to the melter feed, was identified as the primary reason for the previously observed shortfall. The fate of other volatile constituents was also assessed. In particular, in addition to technetium, rhenium, which is frequently used as a non-radioactive surrogate for technetium, was included in these tests. This allows for a direct comparison of the behavior of rhenium and technetium during vitrification and in the down-stream processes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Space Cooling: Recovery, Reuse, Recycling and Supply Chain Impacts

The global cooling sector has undergone tremendous growth in recent years, and cooling demand is projected to double or triple by 2050. Surging air conditioning demand will continue to be driven by increased populations, incomes and occurrences of extreme heat and humidity events. Cooling equipment growth has important pollution and material implications as they are made up of critical metals and precious raw materials - including ferrous metals, copper, aluminum and printed circuit boards composed of copper, silver, gold and palladium - that generate significant electronic waste at end-of-life. Air conditioning equipment also contains fluorinated gas (F-gas) refrigerants, which are potent gases that are thousands of times more heat-trapping than carbon dioxide (CO2). While recovery, reuse, and recycling strategies have been assessed for cold chain and refrigeration, there is currently limited analysis on how these strategies could be adopted for the global space cooling industry and potential supply chain implications. This paper aims to address this research gap by qualitatively evaluating product and material recovery, reuse and recycling frameworks from both demand and supply-side perspectives and with the support of cooling-specific case studies. It also focuses on quantitatively assessing potential energy, emissions and resource benefits of such strategies for space cooling equipment. This paper first analyzes how existing recovery, reuse and recycling frameworks can be applied to space cooling, with emphasis on the demand-side enablers (e.g., innovative business models, supporting policies and regulations) and changes in supply-side production network throughout the supply chain (e.g., design, production and distribution, end-of-life recovery) needed to overcome existing barriers. It will present case studies of innovative business models for space cooling technologies, including reuse and recycling, and how effective refrigerant reclamation and recovery programs have been operationalized. Lastly, the paper will highlight global modeling results of energy, emissions and material recovery from scenario analysis of selected strategies for air conditioners. The findings of this paper are intended to inform the development of product and material recovery, reuse and recycling strategies for a rapidly growing stock of space conditioning equipment by addressing existing organizational, economic and regulatory barriers and potential supply-chain bottlenecks.

Khanna, Nina↗

DOE OSTI2025

Closed‐Loop Recyclable Vitrimer Plastics from PET Waste: A Design for Circularity

Plastics are essential to modern society, but their low recycling rates and inefficient end-of-life management pose a significant environmental challenge. Herein, the efficient strategy for upcycling postconsumer poly(ethylene terephthalate) (PET) waste into robust, closed-loop recyclable vitrimer plastics and composites is presented to address this issue. The catalyst-free aminolysis utilizes readily available amines to deconstruct diverse PET wastes into macromonomers, which are upcycled into vitrimers, exhibiting superior mechanical properties and exceeding the ultimate tensile stress and Young's Modulus of virgin PET by 80% and 150% respectively. These vitrimers exhibit excellent healability, shape memory, thermal reprocessability, and closed-loop chemical recyclability, enabling quantitative macromonomer recovery even from mixed plastic waste streams and glass/carbon fiber reinforced vitrimer (G/CFRV) composites. Furthermore, the vitrimer resin yields robust GFRV and CFRV composites with tensile strengths exceeding those of traditional epoxy composites by 100% and 80%, respectively, while maintaining complete chemical recyclability of both constituent materials. A preliminary technoeconomic analysis confirms the costeffectiveness and competitiveness of the facile PET deconstruction approach, which is potentially adaptable to other condensation polymers. Further, this study presents a facile approach to upcycling plastic waste into circular plastics and composites, offering a sustainable solution to global plastic waste management and fostering a circular economy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Mitigating the Impact of Thermal Binder Removal for Direct Li-Ion Battery Recycling

Li-ion battery recycling will become critical to the management of end-of-life batteries from electric vehicles. Currently, it is a challenge to create a profitable recycling process, which is made more difficult by the reduction in cathode cobalt content. Maintenance of the cathode structure throughout the recycling process can yield increased revenues that may make recycling profitable. This method will require careful removal of the PVDF binder and carbon black, which can be achieved through thermal processing. Furthermore, it is necessary to mitigate the effects of the fluorine from the PVDF on the cathode material. Herein, we report a process that utilizes excess LiOH•H 2 O to react with this fluorine and thereby prevent lithium removal and doping of the cathode material. In addition, we demonstrate a one-step thermal process that can both remove the binder and relithiate the cathode material.

25 ENERGY STORAGE↗

DOE OSTI2019

Ultra High Temperature Anode Recycle Blower for Solid Oxide Fuel Cell (Phase I Final Report)

Under funding from DOE Award DE-FE0031148, Mohawk Innovative Technology, Inc. (MITI) has successfully developed, integrated and tested a prototype ultrahigh speed oil-free blower for use as an Ultra High Temperature Anode Recycle Blower (UHT-ARCB) in a 100 kWe Solid Oxide Fuel Cell (SOFC). MITI’s recycle blower design is hermetically sealed, and features a completely encapsulated permanent magnet motor, which allows it to handle the steam-rich anode recycle gas mixture. At the SOFC’s nominal operating condition, the MITI ARCB rotates at approximately 55000 rpm, raises the pressure of the incoming 621 °C gas from 104 to 112 kPa, and uses less than 1.2 kWe at a rate of approximately 30 g/s. The UHT-ARCB’s thermal management uses the incoming natural gas supply for the SOFC as cooling medium for bearings, seals and motor magnet, along with a water jacket for motor housing cooling to prevent the high temperature gas from affecting the bearing/motor assembly. MITI’s development of this UHT-ARCB will contribute to a reduction of cost and overall balance of plant (BOP) of SOFC systems. The UHT-ARCB recirculates a fraction of the depleted anode exhaust to the fuel-cell inlet. Direct recycling of anode off-gas takes advantage of the water already present in the stream to assist the methane reforming process and inhibit carbon deposition, without the need for an external water supply.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2026

Highly Recyclable Thermosets for Lightweight Composites

The objective of this project, Highly Recyclable Thermosets for Lightweight Composites (DOE Award DE-EE0009297), was to develop recyclable carbon fiber–reinforced polymer (CFRP) composites that are more energy efficient to produce than existing technologies while achieving superior mechanical performance and enabling closed-loop material recovery. Specifically, the project targeted vitrimer-based composites with tensile strength at least 20% higher than baseline recyclable polypropylene composites, retention of greater than 95% of tensile strength after multiple recycling and reprocessing cycles, recovery of carbonate monomers through depolymerization, and recovery of greater than 95% of carbon fibers of reusable quality. The project was carried out by The University of Akron in collaboration with Pacific Northwest National Laboratory and Raytheon Technologies Research Center.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Consumer Guide to Recycling Codes

Learn about the recycling symbols that indicate whether products or packaging can be recycled. This fact sheet from Energy Saver describes the recycling codes for plastic, glass, and paper that indicate how materials should be recycled or disposed of.

recycling, recycling codes, Energy Saver↗

DOE OSTI2021

Integrating Emerging Polymer Chemistries for the Advancement of Recyclable, Biodegradable, and Biocompatible Electronics

Abstract Through advances in molecular design, understanding of processing parameters, and development of non‐traditional device fabrication techniques, the field of wearable and implantable skin‐inspired devices is rapidly growing interest in the consumer market. Like previous technological advances, economic growth and efficiency is anticipated, as these devices will enable an augmented level of interaction between humans and the environment. However, the parallel growing electronic waste that is yet to be addressed has already left an adverse impact on the environment and human health. Looking forward, it is imperative to develop both human‐ and environmentally‐friendly electronics, which are contingent on emerging recyclable, biodegradable, and biocompatible polymer technologies. This review provides definitions for recyclable, biodegradable, and biocompatible polymers based on reported literature, an overview of the analytical techniques used to characterize mechanical and chemical property changes, and standard policies for real‐life applications. Then, various strategies in designing the next‐generation of polymers to be recyclable, biodegradable, or biocompatible with enhanced functionalities relative to traditional or commercial polymers are discussed. Finally, electronics that exhibit an element of recyclability, biodegradability, or biocompatibility with new molecular design are highlighted with the anticipation of integrating emerging polymer chemistries into future electronic devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Phototunable Lignin Plastics to Enable Recyclability

The accumulation of non-degradable petrochemical plastics imposes a significant threat to the environment and ecosystems. We addressed this challenge by designing a new type of phototunable plastics based on the unique lignin chemistry to enable readily end-life recycling. The advanced material design leveraged the efficient photocatalytic lignin depolymerization by ZnO nanoparticles to build lignin-polymethyl methacrylate (PMMA)-ZnO blends. We first demonstrated the highly effective phototunable lignin depolymerization in the complex polymer blend matrix and explored the molecular mechanisms. The technical barriers of mechanical property and recycling processing were then addressed by a new blend design with lignin core grafted with PMMA polymer. The new process has resulted in a new type of PMMA-g-lignin blend, which significantly improved the mechanical properties, making it comparable to PMMA alone. More importantly, the mechanical properties of the UV-treated blend decreased drastically in the new design, whereas the properties did not reduce in the non-grafted blends upon UV exposure. The results highlighted that the new blend design based on graftization maximized the impact of lignin depolymerization on blend structure and recyclability. Based on the results, we developed a process integrating UV and alkaline treatments to recycle PMMA for plastics and fractionated lignin for bioconversion or other applications in the new phototunable plastics.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Effects of Copolymer Structure on Enzyme-Catalyzed Polyester Recycling

Polyesters are an omnipresent material used for a variety of applications (e.g., bottles, packaging, textile, windshield), roughly comprising 8% of plastics produced worldwide. Enzymatic recycling is an emerging solution to deal with the increasingly diverse polyesters that are not suitable for mechanical recycling. However, enzyme activity and efficiency are still the limiting factors impeding enzymatic recycling for different plastic waste forms. The effects of thermal and structural properties (e.g., glass transition temperature, crystallinity, specific surface area), which are determined by chemical composition and preprocessing, directly influence enzyme recycling efficiency. This work investigates two extrusion methods (single screw and twin-screw extrusion) to pretreat a range of copolyesters (RPET, PETG, Ecozen, Tritan and PBT) and modify their properties (i.e., glass transition temperature (T g ), crystallinity (%), and molecular weight (M n )). A PET-specific enzyme, leaf-branch compost cutinase (LCC ICCG ), produced from a fed-batch fermentation of Escherichia coli BL21(DE3), was used for the enzymatic depolymerization of different polyesters. Several copolyesters showed improved depolymerization after pretreatment, as measured by rate and amount of monomers produced. Furthermore, those that did not depolymerize were found to have exceptionally high glass transition temperature or percent crystallinity, highlighting the importance of these physical parameters on conversion efficiency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

A coupled equilibrium boundary layer model with stable water isotopes and its application to local water recycling

The contribution of evapotranspiration (ET) to regional precipitation, known as “local water recycling”, is a key process in the water cycle that can affect water management. However, the amount of planetary boundary layer (PBL) moisture that arises from ET is highly uncertain due to complex atmosphere and land surface conditions. In this study, an idealized two-layer equilibrium boundary layer model was coupled with a stable water isotope module including HDO and H 2 18 O to constrain PBL growing season water transport processes. The model was validated using turbulent heat fluxes and isotope ratios of water vapor (δ m ) and precipitation (δ P ) measured at a cropland site and a nearby tall tower in the Upper Midwest, United States. The results show that the PBL equilibrium features of δ m and δ P are well-constrained by thermal and moisture equilibrium in the PBL. For this study region, the summer values of rain evaporation fraction (f) and local water recycling ratio (LRR) are estimated to be 0.09 and 0.29 ± 0.12, respectively. The summer LRR values for the years 2006–2010 were 0.35, 0.36, 0.17, 0.29, and 0.29, respectively. The small value of LRR in 2008 corresponded to a drought condition with the lowest precipitation and second lowest ET among the five years. The summer magnitude of the amount effect is –2.8‰ (mm day –1 ) –1 and –0.8‰ (mm day –1 ) –1 for HDO and H 2 18 O, respectively. The local water recycling is identified as a significant factor influencing the continental isotope effect. Cropland has likely changed the regional LRR by –7.6 to 19.5% under different pre-agriculture land use scenarios. In conclusion, the feedback processes revealed here indicate that local water recycling is expected to be weakened under drought conditions, but it will be enhanced if irrigation is applied more intensely with more frequent drought events as the climate continues to warm.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Optimising the geospatial configuration of a future lithium ion battery recycling industry in the transition to electric vehicles and a circular economy

Rapid electrification of the transport system will generate substantial volumes of Lithium-ion-battery (LiB) waste as batteries reach their end-of-life. Much attention focuses on the recycling processes, neglecting a broader systemic view that considers the concentration of the costs and impacts associated with logistics and transportation. This paper provides an economic, environmental and geospatial analysis of a future LiB recycling industry in the UK. Hitherto, state-of-the-art assessment methods have evaluated life cycle impacts and costs but have not considered the geographical layer of the problem. This paper develops a GSC derived supply chain model for the UK electric vehicle and end-of-life vehicle battery industry. Considering both pyrometallurgical and hydrometallurgical recycling technologies, the optimisation process takes into account anticipated EV volumes, and, based on anticipated near-term technological evolution of LiBs, the evolution of the mix of battery cathodes in production, and presents a number of scenarios to show where LiB recycling facilities should ideally be geographically located. An economic and environmental assessment based on a customised EverBatt model is provided.

25 ENERGY STORAGE↗

DOE OSTI2026

Covalent adaptable networks for electrolyte–binder integration in recyclable lithium metal batteries

Lithium-metal batteries (LMBs) are considered a promising next-generation energy storage technology due to their exceptionally high energy density. However, the development of solid polymer electrolytes and cathode binders for LMBs faces critical challenges, including interfacial instability, poor recyclability, and growing environmental concerns. In particular, current systems often rely on non-recyclable components featuring permanently crosslinked networks and polyfluoroalkyl substances (PFAS), such as poly(vinylidene fluoride) (PVDF), which cause battery waste and environmental harm. Herein, we introduce a multifunctional covalent adaptable network (CAN) platform based on thermally reversible Diels–Alder (DA) chemistry, designed for dual functionality as a CAN-based electrolyte (CAE) and a CAN-based cathode binder. The CAE achieves high ionic conductivity and strong storage modulus (1.4 mS cm −1 and ∼ 10 5 Pa at room temperature, respectively) and enables stable long-term cycling in symmetric Li||Li cells for over 2000 h with low overpotential. When it is applied as a cathode binder in LiFePO 4 (LFP) composite electrodes (C-LFP), the CAN matrix significantly reduces interfacial resistance and enhances discharge capacity compared to conventional PVDF-based systems. Thermal treatment induces self-healing at the cathode–electrolyte interface, further improving contact and yielding a discharge capacity of 150 mAh g −1 at 0.5 C. Moreover, the dynamic CAN architecture allows efficient recovery and reuse of lithium salts from spent electrolytes through retro-DA reactions under mild conditions (∼80 °C), establishing a low-energy, cost-effective recycling pathway. In conclusion, this work presents a scalable and sustainable strategy for high-performance LMBs by integrating recyclability, interfacial healing, and PFAS-free design, offering a holistic solution aligned with circular economy principles and next-generation battery demands.

Diels–Alder↗

DOE OSTI2026

PET waste- and bio-derived imine vitrimers for shape-memory, intrinsic flame-retardant, and recyclable carbon fiber composites

Developing circular multifunctional vitrimers and carbon fiber–reinforced polymers (CFRPs) that are simultaneously recyclable, mechanically robust, and intrinsically flame retardant remains a major challenge. Here, in this study, we report multifunctional vitrimers and their carbon fiber–reinforced vitrimer (CFRV) composites, where the vitrimer design integrates closed-loop recyclability, enhanced interfacial adhesion, and intrinsic flame retardancy within a single materials platform. The vitrimer matrix is synthesized from post-consumer polyethylene terephthalate (PET) waste and a vanillin-derived phosphorus-containing crosslinker, forming an imine-based network. The resulting vitrimer resin exhibits high tensile strength, thermal healability, repeated reprocessability, programmable shape memory, and rapid chemical depolymerization under mild conditions. Amine-functionalized carbon fibers significantly improve fiber–matrix interfacial bonding, yielding CFRVs with tensile strengths up to 789 MPa and complete recovery of structurally intact fibers after chemical recycling. The phosphorus-rich aromatic network further imparts intrinsic flame retardancy, enabling self-extinguishing behavior without external additives. This work advances a materials design paradigm for next-generation multifunctional, sustainable vitrimers and CFRVs, while simultaneously addressing the recycling challenges associated with both plastic and CFRP waste.

Bio-derived crosslinker↗

DOE OSTI2024

Challenges in the mechanical recycling and upcycling of mixed postconsumer recovered plastics (PCR): A review

The presence of chemically different and compositionally varying plastics in mixed postconsumer recovered plastic (PCR) presents daunting barriers to recycling and upcycling efforts. This review systematically outlines how different processing techniques and characterization methods can be implemented to improve PCR's mechanical recycling and upcycling processes. The review further addresses the recycling challenges in the processing of mixed plastics from PCR and how their mechanical properties can be enhanced by making use of different types of compatibilizers such as copolymers, Janus nanoparticles as well as different approaches such as solid-state pulverization and microfibrillarization. In addition, the state-of-the-art applications of recycled plastics usage in automotive and construction are reviewed.

Compatibilization↗

DOE OSTI2023

Unraveling the nature of sulfide ions in hydrometallurgical recycling of NCM622 cathode material

The use of lithium-ion batteries (LIBs) has increased dramatically since its initial inception in the late 20th century. Such a surge in the LIB market and industry has resulted in a huge demand for mineral resources. Besides, the large scale of production will lead to massive amounts of waste batteries in the end. As such, recycling is seen as an end-of-pipe process to resolve sustainability and environmental concerns. The hydrometallurgical recycling is considered to be the most prominent method to recover cathode materials from spent LIBs owing to its high leaching efficiency and low energy costs. A series of procedures including pretreatment of the spent LIBs, acid leaching of the black mass, chemical co-precipitation of the hydroxide precursor, and sintering of the cathode active material need to be operated precisely. In this aspect, the impurities introduced during the process could pose a serious threat to the reaction stability as well as recycling consistency. Here, the impact of sulfide ions on recovered LiNi 0.6 Co 0.2 Mn 0.2 O 2 (NCM622) cathode material with the method of hydrometallurgy is first investigated in detail. This study shows that hydrometallurgical process is not obviously influenced by sulfide impurity. No signs of secondary phase or impurity inclusion are spotted in synthesized cathodes. Under 5 at % sulfide concentration conditions, the obtained NCM622 cathode exhibits a capacity of 159.4 mAh/g after 100 cycles at 1/3C, which is at the same level as virgin benchmark. The difference in rate performance between cathodes with and without additional sulfide is less than 2 % or even smaller. In short, the results indicate a neutral status of sulfide ions in hydrometallurgical recycling.

25 ENERGY STORAGE↗

DOE OSTI2024

Progress in direct recycling of spent lithium nickel manganese cobalt oxide (NMC) cathodes

With the widespread use of lithium-ion batteries (LIBs) in portable electronics and electric vehicles (EVs), the end-of-life (EOL) LIBs are projected to reach 1336 GWh by 2040 under the sustainable development scenario. Proper recycling is urgently needed to minimize the release of hazardous waste and reduce mining activities by reintroducing critical minerals into the supply chain. Lithium nickel manganese cobalt oxide (LiNi x Mn y Co z O 2 , NMCs) cathodes have become dominant in the LIB market, especially with the increasing production of EVs, which are also the most valuable components in EOL LIBs. Unlike pyrometallurgical and/or hydrometallurgical methods, which convert spent NMCs into metals or metal compounds, direct recycling technologies aim to maximize the value of spent cathodes by restoring their degraded structure and composition. Furthermore, this review summarizes direct recycling methods for NMC cathodes published in the last decade and provides insights into the challenges and future development of direct recycling techniques.

Cathode↗