In recent years, batteries have revolutionized electrification projects and accelerated the energy transition. Consequently, battery systems were hugely demanded based on large-scale electrification projects, leading to significant interest in low-cost and more abundant chemistries to meet these requirements in lithium-ion batteries (LIBs). As a result, lithium iron phosphate (LFP) share has increased considerably due to lower cost and higher safety compared to conventional nickel and cobalt-based chemistries. However, their fast-growing share is affected by updated chemistries, where cheaper systems like sodium-ion batteries (SIBs) are becoming more attractive. SIBs also benefited from the greener, more ethical, and evenly distributed elemental resources. SIBs are fast approaching market thanks to mature LIB’s technology and manufacturing scalability using existing Li-ion gigafactories. Additionally, SIBs can be adapted to other emerging technologies, including Li-ion batteries and silicon-based anodes, influencing projections for their broader use. However, despite the lower cost and abundance of sodium chemistries compared to lithium ones, limited manufacturing capacity discourages material suppliers from increasing production, which restricts the supply chain, raises costs, and diminishes Na battery manufacturing. Here, we aim to provide an overview of the progress of SIBs in gaining market share from LIBs. We first reviewed LIB and SIB histories, developments, and market share. Then, we analyzed the offered chemicals in battery components, their resources and supplies, material demand, and supply chain. The commercialization of each system was investigated in addition to the challenges related to energy density, environmental impact, sustainability, and safety. If all these concerns are addressed properly, LIBs and SIBs could potentially offer a more affordable, safer, and sustainable choice for the global energy storage outlook, particularly in short-range electric vehicles and stationary grid storage.

The pursuit of industrializing lithium-ion batteries (LIBs) with exceptional energy density and top-tier safety features presents a substantial growth opportunity. The demand for energy storage is steadily rising, driven primarily by the growth in electric vehicles and the need for stationary energy storage systems. However, the manufacturing process of LIBs, which is crucial for these applications, still faces significant challenges in terms of both financial and environmental impacts. Our review paper comprehensively examines the dry battery electrode technology used in LIBs, which implies the use of no solvents to produce dry electrodes or coatings. In contrast, the conventional wet electrode technique includes processes for solvent recovery/drying and the mixing of solvents like N-methyl pyrrolidine (NMP). Methods that use dry films bypass the need for solvent blending and solvent evaporation processes. The advantages of dry processes include a shorter production time, reduced energy consumption, and lower equipment investment. This is because no solvent mixing or drying is required, making the production process much faster and, thus, decreasing the price. This review explores three solvent-free dry film techniques, such as extrusion, binder fibrillation, and dry spraying deposition, applied to LIB electrode coatings. Emphasizing cost-effective large-scale production, the critical methods identified are hot melting, extrusion, and binder fibrillation. This review provides a comprehensive examination of the solvent-free dry-film-making methods, detailing the underlying principles, procedures, and relevant parameters.

Direct methanol fuel cells have emerged as highly promising energy conversion devices in the past few decades. However, some challenges, such as carbon monoxide (CO) poisoning and unsatisfactory long-term stability, remain for platinum (Pt) as a methanol oxidation reaction (MOR) catalyst. This review covers recent advances in Pt alloy MOR catalysts and provides some insights. This review presents MOR catalytic mechanisms based on CO or non-CO pathways. Typical dimension-based designs of MOR catalysts, such as anisotropic nanowires, metallene, nanoframes, and corresponding rationales for performance enhancements, are introduced. More importantly, some key tuning strategies are elaborated, including intermetallic compound synthesis, interface engineering, and surface facet engineering. High-entropy alloys as an intriguing class of MOR catalysts with favorable prospects are also discussed. Finally, future directions and opportunities are outlined.

This strategic review examines the pivotal role of sustainable methodologies in battery recycling and the recovery of critical minerals from waste batteries, emphasizing the need to address existing technical and environmental challenges. Through a systematic analysis, it explores the application of green organic solvents in mineral processing, advocating for establishing eco-friendly techniques aimed at clipping waste and boosting resource utilization. The escalating demand for and shortage of essential minerals including copper, cobalt, lithium, and nickel are comprehensively analyzed and forecasted for 2023, 2030, and 2040. Traditional extraction techniques, including hydrometallurgical, pyrometallurgical, and bio-metallurgical processes, are efficient but pose substantial environmental hazards and contribute to resource scarcity. The concept of green extraction arises as a crucial step towards ecological conservation, integrating sustainable practices to lessen the environmental footprint of mineral extraction. The advancement of green organic solvents, notably ionic liquids and deep eutectic solvents, is examined, highlighting their attributes of minimal toxicity, biodegradability, and superior efficacy, thus presenting great potential in transforming the sector. The emergence of organic solvents such as palm oil, 1-octanol, and Span 80 is recognized, with advantageous low solubility and adaptability to varying temperatures. Kinetic (mainly temperature) data of different deep eutectic solvents are extracted from previous studies and computed with machine learning techniques. The coefficient of determination and mean squared error reveal the accuracy of experimental and computed data. In essence, this study seeks to inspire ongoing efforts to navigate impediments, embrace technological advancements including artificial intelligence, and foster an ethos of environmental stewardship in the sustainable extraction and recycling of critical metals from waste batteries.