The rapid development of lithium-ion battery (LiB) recycling highlights its potential for addressing resource scarcity and environmental sustainability. Yet, the lack of systematic, process-specific safety frameworks means that critical hazards are often overlooked. Unlike existing studies that primarily emphasize technological advances, this study explores the process safety of LiB recycling through a struc-tured methodology. We conduct a review to map recycling processes (pretreatment, pyrometallurgy, and hydrometallurgy) and to uniquely identify and categorize the hazards arising from physical and chemical factors in these processes. In this regard, risk analysis was conducted to correlate hazards with potential accident scenarios, supported by accident case studies and industrial safety standards. To address these risks, this paper presents a comprehensive risk mitigation framework that utilizes the hierarchy of controls theory (elimination, substitution, engineering controls, administrative controls, and PPE). This methodology provides actionable recommenda-tions for policymakers and industry practitioners to address existing technological and regulatory gaps to promote safe and sustainable LiB recycling practices. These insights offer new perspectives to the evolving discussion of sustainable energy systems, emphasizing safety as a cornerstone of innovation and implementation.

Low-cost lithium-sulfur batteries (LSBs) with high specific energy density have drawn the attention of the industrial community as lithium-ion batteries get closer to their theoretical limits. However, their commercialization is constrained by the use of lithium metal anodes and the shuttle effect of lithium polysulfides (LiPSs) in redox processes. Ketjenblack (KB) was used in this research work to embed cobalt nanoparticles with a diameter smaller than 40 nm in order to create a suitable and affordable cathode host. Incorporating Co nanoparticles with KB that has a porous structure and great electrical conductivity allows the host to confine LiPSs chemically and physically, which is beneficial for lowering the shuttle effect and lengthening the lifespan of LSBs. Additionally, by using the lithiated form of sulfur (Li2S) rather than sulfur as the cathode material, the lithium source was moved from the anode to the cathode, reducing the safety concerns related to Li metal anodes and enabling the use of non-metallic anode materials like silicon and tin in LSBs. Li2S-Co@KB cathode has an initial discharge capacity of 850.3 mAh gLi2S-1. The cell has shown strong cycling stability at a 0.5 C current rate for over 300 cycles, with low capacity fading of 0.19% per cycle, as well as exceptional C-rate performances up to 5 C.

Lithium ion batteries are considered the most promising energy storage and conversion device candidates for use in future electric vehicle applications due to their ultrahigh energy density. In this study, a facile, ultrafast and green flame spray pyrolysis method was developed well to efficiently fabricate submicron-sized lithium cobaltite spheres from an aqueous spray solution of lithium nitrate and cobalt nitrate. Molar ratios of lithium: cobalt in the precursor solution was altered at three different levels, viz., 1: 1, 1. 3: 1 and 1. 7: 1. Then samples obtained under same conditions were calcined. Also, sample obtained with molar ratios of lithium: cobalt 1. 7: 1, under different conditions atmosphere was calcined. The sample calcined in oxygen atmosphere with low flow was phase pure crystalline rhombohedral lithium cobalt oxide. Furthermore, this sample showed an acceptable performance as cathode active material of lithium ion battery. The rechargeable capacity was 162 mAh g-1 at 0. 1 C and 101 mAh g-1 at 1 C and capacity retention of 84% after 50 cycles at this rate for this sample was observed.

Lithium-iron-orthosilicate is one of the most promising cathode materials for Li-ion batteries due to its safety, environmental brightness and potentially low cost. In order to produce a low cost cathode material, Li2FeSiO4/C samples are synthesized via sol-gel (SG; one sample) and solid state (SS; two samples with different carbon content) methods, starting from Fe(III) as the raw materials (low pristine materials). The three samples are characterized for purity, structure, and morphology. The electrochemical tests showed the different charge-discharge behaviors of the SS and SG samples. Electrochemical behaviors were investigated in terms of voltage vs. square root of capacity diagrams and their slopes. The best results are obtained for the SS sample containing the larger amount of carbon.