Revalorization of graphite fines via carbon nanotube integration for sustainable fast-charging Li-ion battery anodes

In this study, graphite fines—a by-product from the spheroidization of natural graphite—were revalorized into fast-charging anode materials for lithium-ion batteries. A spray-drying method was employed to agglomerate these fines into spherical particles with the addition of 1 wt% carbon nanotubes (CNTs), followed by pitch coating and carbonization at 1100 °C. The resulting GA-CNT@P material exhibited superior rate performance and reduced lithium plating compared to commercial battery-grade natural graphite. Electrochemical tests showed high reversible capacities (∼350 mAh g −1 ), low polarization, and enhanced charge/discharge capabilities, retaining 96 % capacity at 4C discharge and 40 % at 1C charge. Electrochemical impedance spectroscopy revealed reduced solid electrolyte interphase resistance, charge-transfer resistance and Warburg resistance for GA-CNT@P. Differential open-circuit voltage analysis during fast charging indicated a delayed onset of lithium plating and a lower quantity of plated Li compared to the commercial reference. This work demonstrates a scalable, cost-effective strategy to transform graphite waste into high-performance anodes, promoting sustainable battery manufacturing. • Graphite fines revalorized into fast-charging Li-ion battery anodes. • Spray drying yields spherical agglomerates with tailored particle size. • CNT addition and pitch coating enhance rate performance.