Isolating Contiguous Fe Atoms by Forming a Co–Fe Intermetallic Catalyst from Spent Lithium-Ion Batteries to Regulate Activity for Zinc–Air Batteries

The recycling of spent lithium-ion batteries (LIBs) has become a necessity for recovering valuable resources and protecting the environment to support sustainable development. We report the design of a highly efficient CoFe/C catalyst by combining the Co and Fe wastes from spent LIBs with sawdust-derived carbon, which were cathode materials in zinc-air batteries (ZABs). As a result of the electrostatic attraction between the Co3+/Fe3+ cations and the hydroxyl groups in sawdust, CoFe nanoparticles are uniformly dispersed in the CoFe/C catalyst after annealing. The Fe atoms in the CoFe nanoparticles are all isolated into single sites by the Co atoms, which redistribute the electrons in the CoFe/C catalyst. The catalyst produced a Pt-like dissociative mechanism, contributing to an excellent oxygen reduction reaction performance. After assembly in ZABs, the CoFe/C catalyst cathode exhibits a long cycling stability of 350 h and an impressive power density of 199.2 mW cm-2. The CoFe/C catalyst cathode has also been used in flexible ZABs to power LEDs or charge a mobile phone. The work combines spent LIBs with sawdust to fabricate high-performance catalysts, which could reduce environmental pollution and realize high economic value.