Open Access Article
Caspar
de Bruin-Dickason
a,
Serhiy
Budnyk
b,
Jędrzej
Piątek
a,
István-Zoltán
Jenei
a,
Tetyana M.
Budnyak
a and
Adam
Slabon
*a
aDepartment of Materials and Environmental Chemistry, Stockholm University, 10691 Stockholm, Sweden. E-mail: adam.slabon@mmk.su.se
bDepartment of Advanced Chemical Analysis, AC2T Research GmbH, Wiener Neustadt, Austria
First published on 7th September 2020
Cobalt-based Li-ion batteries are produced globally on a massive scale, but most are discarded to landfill at the end of their useful lifetime. In this work, an efficient cobalt catalyst for the hydrolysis of sodium borohydride to dihydrogen was prepared from lithium ion battery waste, providing a second life for valuable minerals. This material is composed of a mixed metal cobalt–aluminium oxide supported on graphene, as elucidated by a combined FTIR, Raman, SEM, scanning transmission electron microscopy with electron energy loss spectroscopy (STEM-EELS) and energy-dispersive X-ray spectroscopy (EDS) study. The obtained metal oxide material, which exhibits an average oxidation state for Co of 2.45, is a languid catalyst at room temperature, but rapid hydrogen production of up to 49 L(H2) min−1 g−1(Co) was observed in catalytic runs heated to 70 °C. This carbon-supported cobalt catalyst is competitive with designed cobalt nanostructured catalysts prepared from pure precursors. This work is illustrative of the opportunities which arise when e-waste is utilised as a mineral resource within the scope of a circular economy.
Cobalt-containing oxides present in lithium ion battery cathodes are prominent in numerous other applications. Cobalt oxides are catalysts for processes such as electrochemical water splitting,10–13 or electrocatalytic water purification.14 Complementary to technology aiming to recover materials are approaches that enable the development of new products directly from waste.15 Relatively few studies have been conducted seeking to find new applications for battery waste. So far, it has been demonstrated that LiCOx from battery waste can be combined with graphene to prepare a highly efficacious lubricant additive,16 that supercapacitor electrodes can be prepared from scrapped LIB cathode materials,17,18 and that MnO2 from Li–MnO2 batteries is a potent catalyst for peroxymonosulfate degradation.19
To explore the possibility of preparing materials relevant to energy transformation directly from e-waste, we have prepared cobalt catalysts for NaBH4 hydrolysis using Co recovered from Li-ion battery cathodes. Hydrolysis of NaBH4 solutions to release hydrogen is accomplished according to Scheme 1, yielding 4 equivalents of H2 per NaBH4 molecule, thereby releasing up to 10.8 wt% H2. While the hydrolysis of NaBH4 is thermodynamically favourable, it is kinetically stable in alkaline solution. In other words, NaBH4 is sufficiently stable in the given timeframe for potential application as a hydrogen source for fuel cells. Hydrolysis (correspondingly, hydrogen evolution) of alkaline borohydride solutions can be readily controlled by the addition and subsequent removal of a solid catalyst.20
Cobalt oxides,21 borides,22 borates23 and Co–P materials (i.e., phosphates, phosphides and mixed phase materials)24 and mixed transition metal borides such as Co–M–B (M = W or Mo)25,26 are potent candidates for heterogeneous earth-abundant metal catalysed hydrogen production from inorganic boranes. These catalysts can be single-phase or alternatively a complex core–shell structure.24 Using a variegated cobalt precursor sourced from battery waste is expected to give rise to new structural diversity and potentially, catalytic properties contrasting those of systems prepared from pure precursors. These cobalt-based catalysts have proven to have similar efficacy at a much lower manufacturing cost point when compared to the precious metal catalysts initially investigated for this purpose. In this work, we have extended this principle by applying simple technology to recover cobalt from a potentially hazardous waste material. Direct treatment of the aqueous cobalt leachate with a sodium borohydride yields a useful catalyst for green hydrogen production. The catalytic and structural properties of this material are discussed herein.
mm mask as incident optics and a parallel plate collimator and a proportional detector as diffracted beam optics. Spectrophotometric analysis of cobalt(II) as 4-(2′-pyridylazo)resorcinol complexes were conducted using a photocolorimeter (WPA, S800) for point measurements at 500 nm in quartz cuvettes as described elsewhere.27 The elemental content of 1C was determined by ICP-OES (iCAP 7400 ICP-OES Duo, Thermo Fisher, Waltham, MA, USA) after microwave supported digestion treatment with nitric acid.
Given the variegated composition of the battery extract, it was essential to thoroughly characterise 1 and 1C to understand their chemical and morphological character. 1 and 1C were characterised variously by SEM, STEM, PXRD, ICP-MS as well as FTIR and Raman spectroscopy. SEM micrographs (Fig. 1) reveal that 1 is composed of nanostructured particle μm clusters of a granular material, whereas 1C is an array of stacked graphene platelets with a lateral size of 100–200 μm, decorated with dispersed metal oxide particles. Based on the SEM images, it appears that metal oxide particles in 1C and 1 are of quite a different morphology, with smaller, powdery clusters present in 1C. ICP-MS analysis of a digested sample of 1C showed that the bulk composition includes by weight: 24.5% Co, 7.8% B and 3.26% Al. Li, Mg, Mn, Fe, and Ni were also detected but were each present at <0.01 wt%. B is super-stoichiometric to cobalt, the two are present in a 1.7
:
1 ratio. This is indicative of the presence of extensive borate phases, as are frequently observed in cobalt materials prepared by borohydride reduction of cobalt salts.23
To further elucidate the composition of 1C, STEM EELS and EDS analysis were performed (Fig. 2). EDS indicated that the primary constituents of 1C were cobalt, oxygen and carbon, with some aluminium and sodium also present. EELS is more accurate for the quantification of low Z elements on the surface of samples. EELS analysis indicated the presence of Co, Li and F. Relative elemental proportions of C, O, F, Na, Al, S and Co are presented in Table 1. A comparison of L2 and L3 edges of Co (Fig. S4, ESI†) using a method developed by Tan et al.,30i.e., energy loss near edge structure (ELNES) fitting, indicated that the average oxidation state of Co is 2.45, indicating a mixture of Co2+ and Co3+ in 1C.
| Element | Atomic fraction (%) |
|---|---|
| C | 32 |
| O | 49 |
| F | 10 |
| Na | 2.7 |
| Al | 2.7 |
| S | 0.2 |
| Co | 4.5 |
Li is difficult to quantify by EELS in the presence of Co. The latter has an M edge at 60 eV, very close to the K edge of Li at 55 eV. As less than 0.1 wt% Li was detected by ICP-MS, EELS quantification of this element was not attempted. The relatively high portion of C detected arises from the necessity of choosing a site with only a very thin metal particle suspended on graphene. On an atom basis, the surface of 1C contains Co
:
F in a 1
:
2 ratio, probably present in the form of Al–F or Co–F moieties. The origin of surface fluoride likely related to the reduction of residual PF6− electrolyte, or from polyvinylidene fluoride – a common binding agent in Li-ion battery cathodes.
Cobalt borates are topical catalysts for borohydride reduction,10,23 so the presence of periodically related Lewis acidic Al sites in 1C may lead to enhanced catalytic activity. A dark field STEM micrograph of 1C is presented in Fig. 2, alongside elemental mapping from STEM-EDS. From the elemental maps, it is evident that Al, Co and O are distributed across the graphene substrate in small clusters, consistent with the small metal–oxide particles observed under SEM (Fig. 1). Notably, the presence of Mn or Ni were detected by either EELS or EDS, confirming that Co is the dominant transition metal component on the surface of the sample. Based on EELS, EDS and ICP-MS analysis, 1C can be described as mixed metal cobalt aluminium borate nanoparticles with fluoride decoration on the surface, supported on graphene.
Spectroscopic analysis was performed to better understand the chemical makeup of 1C. The Raman spectrum of 1C was collected between 1800–400 cm−1, and featured four main bands (Fig. 3). D and G bands of graphene are evident at 1566 and 1336 cm−1; these correspond to aromatic in plane and out of plane vibration modes respectively.31 The prominence of the G band (out of plane) is indicative of lattice defects, indicating some amorphous character to the carbon after treatment with the battery leachate and borohydride. Additional bands at 829 and 699 cm−1 are tentatively assigned to various Co–O modes.
The PXRD pattern of 1C (Fig. 4) features broad peaks centred at θ = 23.7° (002) and 43.8° (101), characteristic of graphitic plates with disordered stacking.32 The position of the 002 peak corresponds to a interlayer d-spacing of 3.8 Å, signifying a lattice extension relative to pristine graphite (graphite features a d-spacing of ca. 3.3 Å). This is typical for graphene aggregates or reduced graphene oxide materials.33 No XRD reflection peaks were able to be unambiguously assignable to metal oxide phases. This originates from the lack of long-range order due to the low temperature of the catalyst synthesis. Consequently, no reflection peaks of potential metal oxide phases can be observed in the XRD patterns.
The FTIR-ATR (Fourier transform infrared – attenuated total reflectance) spectra of 1 and 1C are quite similar (Fig. 5). Both contain diagnostic bands arising from surface adsorbed water are evident at 3494 and 1640 cm−1, and doublets in regions associated with tetrahedral (1420–1320 cm−1) and trigonal borates (1000–905 cm−1),23 indicating the presence of a Con(B3O6) species. The signal for trigonal borates is weaker in 1C than in 1. Shouldering at 850 cm−1 may be associated with alumina species.34
| Catalyst | T | Rate of H2 evolution | |
|---|---|---|---|
| (°C) | L min−1 gcat−1 | L min−1 gCo−1a | |
| a Using 4.5% Co determined by STEM EDS analysis, or as calculated in the literature by authors. b In the un-catalysed run, 4 mL of H2 evolved over 30 minutes, the rate is expressed w.r.t. 1 mg catalyst in line with the other results. c Value given is relative to Pt atoms. | |||
| 1C | 20 | 0.09 | 0.38 |
| 1C | 50 | 1.8 | 7.5 |
| 1C | 60 | 2.0 | 8.1 |
| 1C | 70 | 12 | 49.3 |
| 1C | 80 | 7.6 | 31.1 |
| 1 | 70 | 2.0 | |
| CoCl2·6H2O | 70 | 6.0 | 24 |
| Graphene | 70 | 0.34 | — |
| Blankb | 70 | 0.13b | — |
| CoCl2·6H2O37 | 20 | 0.57 | 2.3 |
| Co–B/Cblack28 | 30 | — | 23.94 |
| Co–O–P24 | 20 | 2.81 | |
| CoO nanocrystals21 | 30 | 5.89 | |
| CoCl2/Al2O338 | 20 | 8.9 | 45.4 |
| Pt/C (10 wt%)39 | 25 | 23 | 176c |
Hydrogen evolution from NaBH4 was then investigated in the presence of 1C, 1, CoCl2·6H2O and graphene at 70 °C (Fig. 6B). Under these conditions, the run impregnated with graphene gave rise to very little hydrogen evolution, comparable to a blank run. 1 is less active than 1C, despite containing a higher portion of cobalt by mass and only achieved 82% conversion of borohydride to hydrogen. The lower performance of 1 despite the significantly higher portion of cobalt present can be related to the large particle sizes observed by SEM. Large particles are typically associated with inferior catalytic performance. The improved durability of 1C relative to 1 supports the postulate that the graphene platelets are effective at stabilising cobalt metal oxide nanoparticles.
The vast majority of studies on cobalt (and other) catalysts for the hydrolysis of borohydrides have investigated their efficacy only between 20–30 °C.20,24 To determine if the more than hundred-fold improvement in hydrogen production rate at 1C upon heating to 70 °C from room temperature is a general feature of cobalt catalysts, or idiosyncratic to this material, we examined the prototypical cobalt catalyst – cobalt chloride.40 At 70 °C, CoCl2 turned over 6.0 L(H2) min−1 g(cat)−1 hydrogen, indicating a 14-fold improvement compared to previous literature reports at 20 °C. The improvement in rate here is an order of magnitude less than that observed for 1C, which is also ten times more active than CoCl2 at 70 °C on a Co atom basis.
To study the long-term stability of 1C, we performed a longer catalytic run (Fig. 6C). In this run, the maximum turnover rate was noted after 15 minutes at 7 L min−1 gcat−1, which then gradually declined to ca. 2 L min−1 gcat−1, a rate still comparable with many literature catalysts. The reaction proceeded to completion with a turnover number of at least 1.2 × 107 in terms of molecules of H2 produced per Co atom in the catalyst.
Most cobalt (and other non-precious metal) systems for borohydride hydrolysis have been benchmarked around room temperature to facilitate straightforward comparison to other systems. The activity of cobalt systems at elevated reaction temperatures is poorly characterised, obfuscating comparisons between literature catalysts and 1C. Developing an understanding of how cobalt catalysts function over long time periods and at elevated temperatures is important if they are to find applications in hydrogen fuel cells. Our results emphasize that valorisation can be considered as sustainable recycling of used Li-ion batteries.41
1C is an effective catalyst for the alkaline hydrolysis of sodium borohydride, achieving an optimal production rate of 49.3 L(H2) min−1 g−1 Co at 70 °C, and a turnover number of at least 1.2 × 107 molecules of H2 per Co atom. A similar catalyst, 1, prepared without a carbon support gave poor turnover and exhibited a relatively lower activity. SEM and STEM analysis showed that metal oxide nanoparticles with smaller particle sizes were obtained in 1C compared to 1, which may explain how the presence of carbon can improve mass activity.
The dramatic improvement in activity of 1C upon heating highlights the need to examine both cobalt and precious metal catalysts over a wide temperature range, as this data will better inform applications in hydrogen on demand systems. Furthermore, this work is illustrative that new possibilities for materials abound when chemists turn their attention to waste as a raw material. Future developments of this system will pursue an optimised synthesis, and seek conditions where long term stability is maximised so that up-cycled cobalt materials such as 1C can be practical components of hydrogen on demand energy systems.
Footnote |
| † Electronic supplementary information (ESI) available: Spectra and photographs of experimental setups. See DOI: 10.1039/d0ma00372g |
| This journal is © The Royal Society of Chemistry 2020 |