Systems and methods for lithium ion battery cathode material recovery, regeneration, and improvement

A cyclone-plasma separator comprising:

• a particle and gas mixer having a particle inlet for introducing a mixture of particles into the particle and gas mixer and a gas inlet for introducing a gas into the particle and gas mixer;
• a cyclone separator chamber downstream of the particle and gas mixer and positioned to receive the mixture of particles and the gas from the particle and gas mixer, the cyclone separator chamber including a vortex finder in a downstream portion of the cyclone separator chamber;
• a plasma reactor comprising a dielectric barrier discharge (DBD) electrode positioned downstream of the particle and gas mixer and upstream of or within the cyclone separator chamber, the DBD electrode adapted to provide a non-equilibrium plasma to the mixture of particles;
• and
• a controller adapted to control one or more of:
• a rate of introducing the mixture of particles into the particle and gas mixer;
• a rate of introducing the gas into the particle and gas mixer;
• a plasma exposure power of the non-equilibrium plasma;
• and
• a plasma exposure timing of the non-equilibrium plasma.

A method of adjusting chemistry of particles of lithium ion battery cathode material having a single, known cathode chemistry, wherein the particles are nanoparticles the method comprising the following steps:

• a) at least partially coating the particles with a Li precursor and a cathode-chemistry-adjusting additive, the at least partially coating achieved by either:
• i) spray drying a suspension comprising a solution of the Li precursor and the cathode-chemistry-adjusting additive having the particles suspended therein;
• or ii) dry mixing the particles with the Li precursor and the cathode-chemistry-adjusting additive;
• b) simultaneous with or subsequent to step a), applying a first elevated temperature to the particles to produce particles at least partially coated with a molten layer of the Li precursor and the cathode-chemistry-adjusting additive;
• and
• c) applying a second elevated temperature and/or a plasma to the particles at least partially coated with a molten layer of the Li precursor and the cathode-chemistry-adjusting additive to produce upgraded lithium ion battery cathode particles.