A dual-cycle regeneration to recover high-value and high-purity FePO4 from real wastewater for Li-battery application

Manipulating electrochemical phosphate recovery from acidic wastewater for synthesizing LiFePO4/C cathode material

Phosphorus (P) recovery from wastewater offers a sustainable solution for mitigating pollution and securing resources for applications like lithium-ion batteries, where ferric phosphate is a valuable precursor. This study evaluates iron electrolysis for P removal and recovery from acidic wastewater with high phosphate concentrations and medium Ca²⁺ levels. The results suggested that effective P removal and high-purity iron phosphate production can be achieved by varying initial pH, current density, and oxidation conditions. Importantly, slow Fe release rates (0.02-0.04 mmol L⁻¹ min⁻¹) favored ferric phosphate formation (71%-77% removal), while faster rates (0.16-0.46 mmol L⁻¹ min⁻¹) predominantly produced vivianite (∼ 65% removal). In addition, air flush can enhance dissolved oxygen flux, achieving 89% P removal under rapid Fe release but with mixed products. H₂O₂ addition improved in situ Fe(II) oxidation, achieving 92% P removal and purer ferric phosphate. Compared to chemical precipitation, which required pH adjustment and suffered from Ca co-precipitation, iron electrolysis produced purer ferric phosphate directly, without pH pre-adjustment. The recovered ferric phosphate showed excellent potential as a precursor for high-performance LiFePO₄/C cathode material. These findings position iron electrolysis as a promising approach for sustainable P recovery and resource valorization from wastewater.

Preparation of High-Purity Nano-Iron Phosphate from Titanium-Extraction Tailings by Co-Leaching Synergetic Ultrasonic-Enhanced Precipitation Process

The preparation of high-performance electrode materials from metallurgical solid waste is an effective strategy to address current energy and environmental challenges. This study utilizes a mixed acid leaching and ultrasound-assisted precipitation process to extract valuable metallic iron from titanium-extraction tailings (TET) to produce high-purity nano-FePO4 electrode material precursors with unique crystal structures. A leaching efficiency of 95.2% for Fe was attained by using the optimized process parameters, which included a mixed acid concentration of 4 mol/L, a liquid-to-solid ratio of 4:1, and a leaching temperature of 70 °C for 1 h. The optimal precipitation conditions were a pH of 2.0, a temperature of 60 °C, an aging time of 30 min, and a stirring speed of 600 rpm, resulting in FePO4 purity up to 99.6% and fine particle size. Thermodynamic calculations, combined with various characterizations, elucidated the leaching and precipitation mechanisms, highlighting the synergistic effect of phosphoric acid and hydrochloric acid in enhancing the leaching reaction. The thermogravimetric analysis indicated that the decomposition of residual ammonium chloride impurities requires calcination above 360 °C. This research not only provides new insights into the high-value, clean utilization of metallurgical solid waste but also supports sustainable resource recovery and environmental protection by transforming waste into valuable products.

Synthesizing LiFePO4 by phosphate & iron recovered from sludge-incinerated ash and Li extracted from concentrated brines

Phosphorus (P) recovered from sludge-incinerated ash (SIA) could be applied to synthesize highly added-value products (FePO4 and LiFePO4) with in situ Fe in SIA. Indeed, LiFePO4 is a future of rechargeable batteries, which makes lithium (Li) highly needed. Alternatively, Li could also be extracted from concentrated brines to face a potential crisis of Li depletion on lands. Based on H3PO4 and Fe3+ co-extracted from the acidic leachate of SIA by tributyl phosphate (TBP), FePO4 (31.2 wt% Fe, 17.6 wt% P and the molar ratio of Fe/P = 0.98) was easily formed only adjusting pH of the stripping solution to 1.6. Interestingly, the organic phase from the first-stage co-extraction process of Fe3+ and H3PO4 could be utilized for Li-extraction from salt-lake brine, based on the TBP-FeCl3-kerosene system, and a good performance (78.7%) of Li-extraction and separation factors (β) (186.0-217.4) were obtained. Furthermore, the compounds with Li-extraction are complex, possibly LiFeCl4∙2TBP, in which Li+ could be stripped to form Li2CO3 by 4.0 M HCl (with a stripping rate up to 83%). Besides, Li2CO3 could also be obtained from desalinated brine by adsorption with manganese oxide ion sieve (HMO) and desorption with HCl. In the two cases, almost pure Li2CO3 products were obtained, up to 99.7 and 99.5 wt% Li2CO3 respectively, after further purification and concentration. Finally, recovered FePO4 and extracted Li2CO3 were synthesized for producing LiFePO4 that had a similar electrochemical property (69.5 and 77.8 mAh/g of the initial discharge capacity) to those synthesized from commercial raw materials.

Enhanced recovery of phosphorus from hypophosphite-laden wastewater via field-induced electro-Fenton coupled with anodic oxidation

Electrochemical recovered ferric phosphate (FePO4) precipitates from hypophosphite-laden wastewater were shown to be an efficient method for phosphorus (P) recovery. However, the influence of chloride ions (Cl-) coexisting commonly in wastewater is not known for this treatment. Herein, a field-induced electro-Fenton coupled with anodic oxidation electrochemical system consisting of a Ti-RuO2 anode, an Fe inductive electrode and an activated carbon fiber (ACF) cathode, namely Ti-RuO2/Fe/ACF(NaCl) system, was established to recover phosphorus (P) as FePO4 from hypophosphite-laden wastewater in the presence of Cl-. This system enabled a hypophosphite (H2PO2-, 1.0 mM) removal ratio of ~100% and all P was recovered within 30 min at 5.0 V under the initial solution pH of 3.0. The Faradaic efficiency and energy consumption of P recovery achieved the maximum value (~94%) and the lowest value (~16 kW h kg-1 P), respectively. Reactive oxygen species including 1O2, FeIVO2+, •O2- and •OH contribute to convert H2PO2- to PO43-, which immediately formed FePO4 with the generated Fe3+ at the optimized conditions. Therein, the contribution of non-radical 1O2 was very considerable. This system exhibited good stability. The efficiency and cost for treatment of actual hypophosphite-laden wastewater were addressed to check its applicability for P recovery.

Cooperation of ferrous ions and hydrated ferric oxide for advanced phosphate removal over a wide pH range: Mechanism and kinetics

Excessive phosphate loading leads to eutrophication problems in rivers or lakes and causes serious environmental and economic damages, urging new technologies to reduce effluent phosphate at ultra-low levels. As a promising candidate, adsorption over metal oxides is restricted by the released hydroxide anions (OH-) through ligand exchange, which elevates pH and suppresses further adsorption. In this contribution, we found ferrous ions (Fe2+) significantly enhance phosphate removal over hydrated ferric oxide (HFO) in a wide pH range via a cooperation of adsorption and precipitation, and clarified the synergistic mechanism by a series of characterizations and the modified models of adsorption isotherms and pseudo second-order kinetics. The combination of Fe2+and HFO removed up to 51.7 mg/g of phosphate at pH 4.0, with 43.6 and 8.1 mg/g attributing to adsorption and precipitation, respectively. In comparison to HFO alone, HFO/Fe2+ system achieved 2.2-fold increase in phosphate removal, 1.9-fold increase in phosphate adsorption capacity, and 3.4-fold increase in phosphate removal rate. The enhancement is understood by that hydroxide anions released from ligand exchange over HFO are neutralized by protons produced from the oxidative precipitation of ferrous ions. The HFO/Fe2+ combining system is promising to realize advanced removal of low concentration phosphate containing wastewater, and these findings bring new insights for the development of novel phosphate removal technologies through a rational design of a combination process.