Unveiling electrochemical insights of lithium manganese oxide cathodes from manganese ore for enhanced lithium-ion battery performance

Implementing manganese-based electrode materials in lithium-ion batteries (LIBs) faces several challenges due to the low grade of manganese ore, which necessitates multiple purification and transformation steps before acquiring battery-grade electrode materials, increasing costs. At present, most Lithium Manganese Oxide (LMO) materials are synthesized using electrolytic manganese dioxide, and the development of new processes, such as hydrometallurgical processes is important for achieving a cost-effective synthesis of LMO materials. In this work, we develop a full synthesis process of LMO materials from manganese ore, through acid leaching, forming manganese sulfate monohydrate (MnSO₄·H₂O), an optimized thermal decomposition (at 900, 950 or 1000 °C) producing different Mn₃O₄ materials and a solid-state reaction, achieving the synthesis of LMO. The latter was used as a cathode material for LIB exhibiting a specific capacity comparable to the state-of-the-art LMO cathode with a remarkable cycling stability of 800 cycles with <20 % in capacity loss. These performances were attributed to the excellent redox reversibility of the LMO cathode, characterized by voltammetry and in operando and in situ characterization by Raman and XRD.