Abstract: Methods of producing sodium hydroxide (NaOH) or lithium hydroxide (LiOH), and sulfuric acid (H2SO4), include generating sodium sulfate (Na2SO4) or lithium sulfate (Li2SO4) from battery manufacturing and recycling and converting the generated Na2SO4 or Li2SO4 to NaOH, LiOH, and H2SO4 via an electrochemical salt-splitting process. The processing steps can be carried out in a closed system such that the generated Na2SO4 or Li2SO4 can be used in the conversion process with optional purification steps. In particular, the LiOH, NaOH, and Na2SO4 are recycled into battery recycling or battery manufacturing processes.

Abstract: A method comprises: providing a metal salt solution including nickel, cobalt, manganese, aluminum, or a combination thereof; combining the metal salt solution with a basic solution wherein the combination of the metal salt solution and the basic solution is maintained at a pH of no greater than 10 to form a metal hydroxide precursor. To form cathode active material the method further includes adding a lithium compound to the metal hydroxide precursor to form a metal hydroxide precursor mixture; and heat-treating the metal hydroxide precursor mixture to form the single-crystal cathode active material.