Co-precipitation and Lithiation of Li(Ni₀.₈₈Co₀.₀₉Mn₀.₀₃)O₂ Using Recycled Metal Sulfates from Black Mass: Impact of Impurities on Electrochemical Performance

A novel synthesis approach for Ni-rich Li(Ni₀.₈₈Co₀.₀₉Mn₀.₀₃)O₂ (NCM88) cathode material is presented, utilizing recycled authentic metal sulfate solution from lithium-ion battery (LIB) recycling process. The cathode materials with two different particle sizes were synthesized via the co-precipitation method from this solution, with the target chemistry of NCM88. Key aim was to understand the role of impurities. Furthermore, the effects of particle size and washing on the electrochemical performance of NMC88 were evaluated. Based on the results, washing of material affected the electrochemical performance and cyclability. Initial discharge capacities of 203.9 mAh g⁻¹ and 206.9 mAh g⁻¹ were achieved for unwashed NCM88 samples with D₅₀ particle sizes of 10 µm and 5 µm, respectively. However, after 62 cycles, these samples exhibited reduced capacity retention, with efficiencies of 83.3% and 86.4%. In contrast, washed samples demonstrated significantly improved performance, attributed to the removal of surface impurities, achieving retention efficiencies exceeding 90%. Notably, the washed NCM88 cathode synthesized from the recycled MeSO₄ solution and featuring a D₅₀ particle size of 5 µm exhibited the highest retention capacity of 95% after 62 cycles. This enhancement is likely due to the smaller particle size, which facilitates better structural stability and electrochemical performance.