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Molten Salt Method Revives EV Battery Cathodes, Restoring Structure and Capacity

A lab study from Huazhong University reports direct regeneration of NCM811 cathodes using a ternary molten salt, leaving industrial validation and life‑cycle assessment to come.

Overview

  • The process repairs end‑of‑life LiNi0.8Co0.1Mn0.1O2 (NCM811) cathodes rather than breaking them down, recovering their ordered layered crystal structure.
  • A ternary molten salt of lithium hydroxide, lithium nitrate, and lithium salicylate enables lithium‑ion transport into damaged material and removes the surface rock‑salt layer.
  • Regenerated cathodes delivered an initial discharge capacity of 196 mAh/g and retained 76% after 200 charge–discharge cycles in laboratory testing.
  • The technique operates at relatively lower temperatures and avoids strong acids or toxic solvents, suggesting reduced energy use and environmental impact pending full analyses.
  • Findings were published in Energy & Environment Nexus on Oct. 16, 2025, with the team planning process optimization, pilot‑scale evaluation, and comprehensive life‑cycle and cost assessments.