There are provided processes for preparing a metal hydroxide comprising (i) at least one metal chosen from nickel and cobalt and optionally (ii) at least one metal chosen from manganese, lithium and aluminum, the process comprising: reacting a metal sulfate comprising (i) at least one metal chosen from nickel and cobalt and optionally (ii) at least one metal chosen from manganese, lithium and aluminum with lithium hydroxide, sodium hydroxide and/or potassium hydroxide and optionally a chelating agent in order to obtain a solid comprising the metal hydroxide and a liquid comprising lithium sulfate, sodium sulfate and/or potassium sulfate; separating the liquid and the solid from one another to obtain the metal hydroxide; submitting the liquid comprising lithium sulfate, sodium sulfate and/or potassium sulfate to an electromembrane process for converting the lithium sulfate, sodium sulfate and/or potassium sulfate into lithium hydroxide, sodium hydroxide and/or potassium hydroxide respectively; reusing the sodium hydroxide obtained by the electromembrane process for reacting with the metal sulfate; and reusing the lithium hydroxide obtained by the electromembrane process for reacting with the metal sulfate and/or with the metal hydroxide.

A positive electrode active material precursor for a nonaqueous electrolyte secondary battery is provided that includes a nickel-cobalt-manganese carbonate composite represented by general formula Ni.sub.xCo.sub.yMn.sub.zM.sub.tCO.sub.3 (where x+y+z+t=1, 0.05≤x≤0.3, 0.1≤y≤0.4, 0≤t≤0.1, and M denotes at least one additional element selected from a group consisting of Mg, Ca, Al, Ti, V, Cr, Zr, Nb, Mo, and W) and a hydrogen-containing functional group. The ratio H/Me of the amount of hydrogen H to the amount of metal components Me included in the positive electrode active material precursor is less than 1.60. The positive electrode active material further includes a secondary particle formed by a plurality of primary particles that have been aggregated.

A more efficient and lower cost method for producing electrochemically stable, and thus safe from thermal runaway, high electrochemical capacity coated lithium nickelate is disclosed. The coated nickelate hydroxide particles are formed from a mixed metal sulfate solution (MMS) serving as the starting material that is obtained from recycled lithium ion and/or nickel metal hydride batteries. The coating of the particles includes a relatively small amount of cobalt/manganese oxide forming the surface of the nickelate particles, while the core of the particles includes a relatively large amount of nickel in relation to the weight of the coating. Battery cathode electrodes may be manufactured by using the obtained coated lithium nickelate particles as the cathode active material (CAM) in forming the battery cathodes.

Provided is a precursor of a positive electrode active material containing, in a reduced amount, impurities which do not contribute to a charge/discharge reaction but rather corrode a firing furnace and peripheral equipment and thus having excellent battery characteristics and safety, and production method thereof.

A method for producing a precursor of a positive electrode active material for nonaqueous electrolyte secondary batteries having a hollow structure or porous structure includes obtaining the precursor by washing nickel-manganese composite hydroxide particles having a particular composition ratio and a pore structure in which pores are present within the particles with an aqueous carbonate solution having a carbonate concentration of 0.1 mol/L or more.

There are provided processes for preparing a metal hydroxide comprising (i) at least one metal chosen from nickel and cobalt and optionally (ii) at least one metal chosen from manganese, lithium and aluminum, the process comprising: reacting a metal sulfate comprising (i) at least one metal chosen from nickel and cobalt and optionally (ii) at least one metal chosen from manganese, lithium and aluminum with lithium hydroxide, sodium hydroxide and/or potassium hydroxide and optionally a chelating agent in order to obtain a solid comprising the metal hydroxide and a liquid comprising lithium sulfate, sodium sulfate and/or potassium sulfate; separating the liquid and the solid from one another to obtain the metal hydroxide; submitting the liquid comprising lithium sulfate, sodium sulfate and/or potassium sulfate to an electromembrane process for converting the lithium sulfate, sodium sulfate and/or potassium sulfate into lithium hydroxide, sodium hydroxide and/or potassium hydroxide respectively; reusing the sodium hydroxide obtained by the electromembrane process for reacting with the metal sulfate; and reusing the lithium hydroxide obtained by the electromembrane process for reacting with the metal sulfate and/or with the metal hydroxide.

Improved methods for preparing lithium transition metal oxide particulate such as lithium nickel metal cobalt oxide (“NMC”) for use in lithium batteries and other applications are disclosed. The lithium transition metal oxide particulate is prepared from appropriate transition metal oxide and Li compound precursors mainly using dry, solid state processes including dry impact milling and heating. Further, novel precursor particulates and novel methods for preparing precursor particles for this and other applications are disclosed.

A compound represented by Li.sub.aCo.sub.(1-x-2y)Me.sub.x(M1M2).sub.yO.sub.δ, (Formula (I)) wherein Me, is one or more of Li, Mg, Al, Ca, Ti, Zr, V, Cr, Mn, Fe, Ni, Cu, Zn, Ru and Sn, and wherein 0≤x≤0.3, 0<y≤0.4, 0.95≤α≤1.4, and 1.90≤δ≤2.10 is disclosed. Further, particles including such compounds are described.

Simple, material-efficient microgranulation methods are disclosed for aggregating precursor particles into larger product particles with improved properties and, in some instances, novel structures. The product particles are useful in applications requiring uniform, smooth, spherical, or rounded particles such as for electrode materials in lithium batteries and other applications.

A mixed conductor, a method of preparing the same, and a cathode, a lithium-air battery, and an electrochemical device each including the mixed conductor. The mixed conductor is represented by Formula 1 and having electronic conductivity and ionic conductivity:
Li.sub.xMO.sub.2-δ  Formula 1 wherein, in Formula 1, M is a Group 4 element, a Group 5 element, a Group 6 element, a Group 7 element, a Group 8 element, a Group 10 element, a Group 11 element, a Group 12 element, or a combination thereof, and 0<x<1 and 0≤δ≤1 are satisfied.

Supplemental lithium can be used to stabilize lithium ion batteries with lithium rich metal oxides as the positive electrode active material. Dramatic improvements in the specific capacity at long cycling have been obtained. The supplemental lithium can be provided with the negative electrode, or alternatively as a sacrificial material that is subsequently driven into the negative electrode active material. The supplemental lithium can be provided to the negative electrode active material prior to assembly of the battery using electrochemical deposition. The positive electrode active materials can comprise a layered-layered structure comprising manganese as well as nickel and/or cobalt.