O3-type layered oxide materials are considered to be a highly suitable cathode for sodium-ion batteries (NIBs) due to their appreciable specific capacity and energy density. However, rapid capacity fading caused by serious structural changes and interfacial degradation hampers their use. A novel Sn-modified O3-type layered NaNi_1/3Fe_1/3Mn_1/3O₂ cathode is presented, with improved high-voltage stability through simultaneous bulk Sn doping and surface coating in a scalable one-step process. The bulk substitution of Sn⁴⁺ stabilizes the crystal structure by alleviating the irreversible phase transition and lattice structure degradation and increases the observed average voltage. In the meantime, the nanolayer Sn/Na/O composite on the surface effectively inhibits surface parasitic reactions and improves the interfacial stability during cycling. A series of Sn-modified materials are reported. An 8%-Sn-modified NaNi_1/3Fe_1/3Mn_1/3O₂ cathode exhibits a doubling in capacity retention increase after 150 cycles in the wide voltage range of 2.0-4.1 V vs Na/Na⁺ compared to none, and 81% capacity retention is observed after 200 cycles in a full cell vs hard carbon. This work offers a facile process to simultaneously stabilize the bulk structure and interface for the O3-type layered cathodes for sodium-ion batteries and raises the possibility of similar effective strategies to be employed for other energy storage materials.

As electric vehicles become more widely used, there is a higher demand for lithium‐ion batteries (LIBs) and hence a greater incentive to find better ways to recycle these at their end‐of‐life (EOL). This work focuses on the process of reclamation and re‐use of cathode material from LIBs. Black mass containing mixed LiMn₂O₄ and Ni_0.8Co_0.15Al_0.05O₂ from a Nissan Leaf pouch cell are recovered via two different recycling routes, shredding or disassembly. The waste material stream purity is compared for both processes, less aluminium and copper impurities are present in the disassembled waste stream. The reclaimed black mass is further treated to reclaim the transition metals in a salt solution, Ni, Mn, Co ratios are adjusted in order to synthesize an upcycled cathode, LiNi_0.6Mn_0.2Co_0.2O₂ via a co‐precipitation method. The two reclamation processes (disassembly and shredding) are evaluated based on the purity of the reclaimed material, the performance of the remanufactured cell, and the energy required for the complete process. The electrochemical performance of recycled material is comparable to that of as‐manufactured cathode material, indicating no detrimental effect of purified recycled transition metal content. This research represents an important step toward scalable approaches to the recycling of EOL cathode material in LIBs.

The recycling of lithium-ion batteries presents challenges due to the complex composition of waste streams generated by current processes. Achieving higher purity levels, particularly in the reclamation of aluminium metal and transition metal black mass, is essential for improved valorisation. In this study, we propose a high-efficiency, low-energy, and environmentally friendly method using organic acids to separate cathodic black mass from the aluminium current collector. The acids selected in this study all show >86% peeling efficiency with acetic acid showing 100% peeling efficiency of black mass from the current collector. The recovered materials were subjected to X-ray diffraction, electron microscopy, and elemental analysis techniques. We show that oxalic-acid-treated material exhibited two distinct active material components with a minimal change in mass ratio compared to the untreated material. We show by elemental analysis of the leachates that the majority of critical materials were retained in the black mass and limited aluminium was leached during the process, with almost 100% of Al recovery achieved. This methodology enables the production of high-purity concentrated aluminium and critical metal feedstocks (Mn, Co, Ni, and Li) for further hydro-metallurgical processes, upcycling of the cathode material, and direct recycling. The proposed approach offers significant potential for enhancing valorization in lithium-ion battery recycling, facilitating efficient separation and optimal recovery of valuable metals.

As Sodium‐ion battery (SIB) technology progresses toward commercial viability, sustainable end‐of‐life (EOL) management is critical. Methods for recycling key components such as hard carbon (HC), a negative electrode material, remain underexplored. This study introduces a direct and efficient recycling approach for HC from production scrap and EOL cells using “ice‐stripping” followed by a low‐temperature binder negation at 300 °C under nitrogen. The effects of temperature on HC structural integrity and electrochemical performance are comprehensively characterized using XRD, Wide‐Angle X‐ray Scattering (WAXS), and XPS. Heating above 400 °C induces irreversible damage to HC's graphene layers and modifies the carbon surfaces, resulting in poor electrochemical performance. However, HC reclaimed at 300 °C retains near‐pristine electrochemical performance, with capacities of 243 mAh g⁻¹ (scrap) and 228 mAh g⁻¹ (EOL) after 50 cycles. Full‐cell configurations demonstrates robust cycling stability, with 86% and 89% capacity retention after 200 cycles for HC derived from scrap and EOL cells, respectively. This work highlights the potential of lower‐temperature, direct recycling to enable a circular economy for SIBs. The findings set a benchmark for developing sustainable recycling methods for HC and other SIB components.