Resource Recovery and Synthesis of Battery-Grade FePO 4 from Waste LiFePO 4 Battery Slag

Puliang Li, Yang Wang, Liying Zhu, Kun Zhang, Weifang Liu (), Tao Chen and Kaiyu Liu ()
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Puliang Li: College of Chemistry and Chemical Engineering, Central South University, Changsha 410083, China
Yang Wang: College of Chemistry and Chemical Engineering, Central South University, Changsha 410083, China
Liying Zhu: Beijing Institute of Spacecraft System Engineering, Beijing 100094, China
Kun Zhang: Beijing Institute of Spacecraft System Engineering, Beijing 100094, China
Weifang Liu: College of Chemistry and Chemical Engineering, Hunan University of Science & Technology, Xiangtan 410082, China
Tao Chen: College of Chemistry and Chemical Engineering, Central South University, Changsha 410083, China
Kaiyu Liu: College of Chemistry and Chemical Engineering, Central South University, Changsha 410083, China

Energies, 2025, vol. 18, issue 7, 1-12

Abstract: The effective recovery of valuable materials from spent LiFePO 4 batteries is crucial for resource sustainability and environmental protection. This study investigates the recovery of phosphorus iron slag from waste LiFePO 4 batteries, focusing on dissolution and impurity removal processes to produce battery-grade iron phosphate. Using high-temperature-activated dissolution, followed by precipitation/dissolution for impurity removal, we optimize conditions to ensure high recovery rates (up to 98.8% for FePO 4 under optimized conditions) and product purity. Our findings demonstrate that the proposed method effectively transforms waste slag into valuable iron phosphate, significantly reducing raw material costs and contributing to sustainable battery recycling practices. The regenerated LiFePO 4 cathode exhibits excellent electrochemical performance, achieving a discharge capacity of 160.7 mAh g −1 at 0.1 C, which meets market standard levels. This research provides a solid foundation for enhancing resource utilization and advancing circular economy principles in the battery industry.

Keywords: lithium-ion batteries; resource recovery; LiFePO 4 cathode; recycling (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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