Recycling of activated carbons from spent supercapacitors to refabricate improved supercapacitors

The growing market of commercial electric double-layer capacitors (EDLCs) will lead to a vast accumulation of waste as they arrive out of operation. Recycling the spent electrode activated carbon is a closed-loop solution to provide environmental and economic advantages for EDLC use. However, effectively regenerated methods of high-purity activated carbons are still lacked despite their considerable expense. Herein, a simple steam physical activation method is developed to regenerate high-class activated carbons from spent EDLCs. The process is first demonstrated that can effectively eliminate few electrolytes and complex organics as well as regenerate electrode carbon materials. The activation-recycled carbon materials preserve the physicochemical properties of fresh activated carbons and enhance their mesopore ratios, which contributes to improved EDLC performance, obviously surpassing recycled carbon materials by calcination method, including superior specific capacitance of 103.3 F g⁻¹ at 0.5 A g⁻¹, rate performance and cycling stability, equal to fresh activated carbons. Moreover, the assembled activation-recycled carbon material EDLC delivers low self-discharge rate (89 % of initial voltage after 72 h), wide temperature range (−40 to 85 °C), excellent cycling stability (92.2 % capacitance retention after 10,000 cycles) even at elevated voltages (3.0 V) and temperature (65 °C) test. The present work provides an effective and economic method of recycling high-grade activated carbons for sustainable EDLCs.