A clean and sustainable method for recycling of lithium from spent lithium iron phosphate battery powder by using formic acid and oxygen

With the widespread adoption of lithium iron phosphate (LiFePO4) batteries, the imperative recycling of LiFePO4 batteries waste presents formidable challenges in resource recovery, environmental preservation, and socio-economic advancement. Given the current overall lithium recovery rate in LiFePO4 batteries is below 1 %, there is a compelling demand for an eco-friendly, cost-efficient, and sustainable solution. This study introduces a green and sustainable recycling method that employs environmentally benign formic acid and readily available oxygen as reaction agents for selectively leaching lithium from discarded lithium iron phosphate powder. Formic acid was employed as the leaching agent, and oxygen served as the oxidizing agent. Utilizing a single-factor variable approach, various factors including formic acid concentration, oxygen flow rate, leaching time, liquid-to-solid ratio, and reaction temperature were individually investigated. Moreover, the feasibility of this method was explored mechanistically by analyzing E-pH diagrams of the Li-Fe-P-H2O system. Results demonstrate that under conditions of 2.5 mol/L formic acid concentration, 0.12 L/min oxygen flow rate, 25 mL/g liquid-to-solid ratio, 70 °C reaction temperature, and 3 h reaction time, lithium leaching efficiency exceeds 99.9 %, with iron leaching efficiency only at 1.7 %. Moreover, we also explored using air instead of oxygen as the oxidant and get the excellent lithium leaching rate (97.81 %) and low iron leaching rate (4.81 %), which shows the outstanding selectivity. Furthermore, the environmentally benign composition of the chemical reagents, comprising only C, H, and O elements, establishes it as a genuinely green and sustainable technology for secondary resource recovery. It can be considered as a highly environmentally friendly, cost-effective, and efficient approach. Nevertheless, in the current context of carbon neutrality and sustainable development, this method undoubtedly holds excellent prospects for industrialization.

Closed-loop recycling of lithium iron phosphate cathodic powders via citric acid leaching

Lithium recovery from Lithium-ion batteries requires hydrometallurgy but up-to-date technologies aren't economically viable for Lithium-Iron-Phosphate (LFP) batteries. Selective leaching (specifically targeting Lithium and based on mild organic acids and low temperatures) is attracting attention because of decreased environmental impacts compared to conventional hydrometallurgy. This study analysed the technical and economic performances of selective leaching with 6%vv. H2O2 and citric acid (0.25-1 M, 25 °C, 1 h, 70 g/l) compared with conventional leaching with an inorganic acid (H2SO4 1 M, 40 °C, 2 h, 50 g/l) and an organic acid (citric acid 1 M, 25 °C, 1 h, 70 g/l) to recycle end of life LFP cathodes. After conventional leaching, chemical precipitation allowed to recover in multiple steps Li, Fe and P salts, while selective leaching allowed to recover Fe and P, in the leaching residues and required chemical precipitation only for lithium recovery. Conventional leaching with 1 M acids achieved leaching efficiencies equal to 95 ± 2% for Li, 98 ± 8% for Fe, 96 ± 3% for P with sulfuric acid and 83 ± 0.8% for Li, 8 ± 1% for Fe, 12 ± 5% for P with citric acid. Decreasing citric acid's concentration from 1 to 0.25 M didn't substantially change leaching efficiency. Selective leaching with citric acid has higher recovery efficiency (82 ± 6% for Fe, 74 ± 8% for P, 29 ± 5% for Li) than conventional leaching with sulfuric acid (69 ± 15% for Fe, 70 ± 18% for P, and 21 ± 2% for Li). Also, impurities' amounts were lower with citric acid (335 ± 19 335 ± 19 of S mg/kg of S) than with sulfuric acid (8104 ± 2403 mg/kg of S). In overall, the operative costs associated to 0.25 M citric acid route (3.17€/kg) were lower compared to 1 M sulfuric acid (3.52€/kg). In conclusion, citric acid could be a viable option to lower LFP batteries' recycling costs, and it should be further explored prioritizing Lithium recovery and purity of recovered materials.

Determination of lithium ions by stripping voltammetry using single-crystal LiFePO4

Determination of lithium ions is very important for extraction of lithium from salt lakes. Electrochemical sensor is an ideal choice, but it is not available so far. Here, a voltammetric sensor based on lithium iron phosphate (LiFePO4) was developed. Single-crystal LiFePO4 dominated by the (010) lattice plane was synthesized using hydrothermal method; it had good selectivity for lithium ions. Lithium ions were preferentially intercalated into LiFePO4 even if molar ratio of sodium ions, potassium ions, magnesium ions or calcium ions to lithium ions reached 10:1. The intercalation and deintercalation of interfering ions should be avoided because this reduced the selectivity of LiFePO4 for lithium ions. Lithium ion concentration of synthetic Uyuni Salt Lake solution was determined using the standard addition method. The measurement result was only 0.34 % higher than the theoretical value. The sensor provides a highly selective lithium ion analysis method at an extremely low cost, which was very promising to be widely used.

Direct lithium extraction from spent batteries for efficient lithium recycling

The flourishing expansion of the lithium-ion batteries (LIBs) market has led to a surge in the demand for lithium resources. Developing efficient recycling technologies for imminent large-scale retired LIBs can significantly facilitate the sustainable utilization of lithium resources. Here, we successfully extract active lithium from spent LIBs through a simple, efficient, and low-energy-consumption chemical leaching process at room temperature, using a solution comprised of polycyclic aromatic hydrocarbons and ether solvents. The mechanism of lithium extraction is elucidated by clarifying the relationship between the redox potential and extraction efficiency. More importantly, the reclaimed active lithium is directly employed to fabricate LiFePO4 cathode with performance comparable to commercial materials. When implemented in 56 Ah prismatic cells, the cells deliver stable cycling properties with a capacity retention of ∼90% after 1200 cycles. Compared with the other strategies, this technical approach shows superior economic benefits and practical promise. It is anticipated that this method may redefine the recycling paradigm for retired LIBs and drive the sustainable development of industries.

A review on the recycling of spent lithium iron phosphate batteries

Lithium iron phosphate (LFP) batteries have gained widespread recognition for their exceptional thermal stability, remarkable cycling performance, non-toxic attributes, and cost-effectiveness. However, the increased adoption of LFP batteries has led to a surge in spent LFP battery disposal. Improper handling of waste LFP batteries could result in adverse consequences, including environmental degradation and the mismanagement of valuable secondary resources. This paper presents a comprehensive examination of waste LFP battery treatment methods, encompassing a holistic analysis of their recycling impact across five dimensions: resources, energy, environment, economy, and society. The recycling of waste LFP batteries is not only crucial for reducing the environmental pollution caused by hazardous components but also enables the valuable components to be efficiently recycled, promoting resource utilization. This, in turn, benefits the sustainable development of the energy industry, contributes to economic gains, stimulates social development, and enhances employment rates. Therefore, the recycling of discarded LFP batteries is both essential and inevitable. In addition, the roles and responsibilities of various stakeholders, including governments, corporations, and communities, in the realm of waste LFP battery recycling are also scrutinized, underscoring their pivotal engagement and collaboration. Notably, this paper concentrates on surveying the current research status and technological advancements within the waste LFP battery lifecycle, and juxtaposes their respective merits and drawbacks, thus furnishing a comprehensive evaluation and foresight for future progress.

Enabling high-performance lithium iron phosphate cathodes through an interconnected carbon network for practical and high-energy lithium-ion batteries

The olivine lithium iron phosphate (LFP) cathode has gained significant utilization in commercial lithium-ion batteries (LIBs) with graphite anodes. However, the actual capacity and rate performance of LFP still require further enhancement when combined with high-capacity anodes, such as silicon (Si) anodes, to achieve high-energy LIBs. In this study, we introduce a gelatin-derived carbon network into a nanosized LFP cathode without the need for additional binding and conductive agents, employing a simple and cost-effective method. The resulting cathode exhibits an extremely high LFP content (∼92.3 wt%), enabling it to show a high real capacity of 159.7 mAh/g at 0.2 C in half cells. Additionally, the interconnected carbon network effectively facilitates electron and Li+ transport, providing rapid pathways within the LFP nanoparticles. Consequently, the cathode exhibits superior rate capability (107.3 mAh/g at 10 C) and good cycling performance (with a capacity retention of ∼ 80 % after 500 cycles). To further assess its practical viability, the LFP cathode is assembled into a full cell utilizing a Si-based anode with a N/P ratio of 1.1. The resulting full cell delivers a significantly high energy density of 419.7 Wh kg-1, coupled with prolonged cycle life, highlighting its promising prospects for practical applications.

Prominent enhancement of stability under high current density of LiFePO4-based multidimensional nanocarbon composite as cathode for lithium-ion batteries

A facile method for synthesizing carbon-coated lithium iron phosphate (LiFePO4, LFP) and an LFP-based multidimensional nanocarbon composite to enhance the electrochemical performance of lithium-ion batteries is presented herein. Three types of cathode materials are prepared: carbon-coated LFP (LC), carbon-coated LFP with carbon nanotubes (LC@C), and carbon-coated LFP with carbon nanotubes/graphene quantum dots (LC@CG). The electrochemical performances of the LC-nanocarbon composites are compared, and both LC@C and LC@CG show improved electrochemical performance than LC. Compared with both the LC and LC@C electrodes, the LC@CG electrode exhibits the highest specific capacity of 107.1 mA h g-1 under 20C of current density, as well as higher capacities and greater stability over all measured current densities. Moreover, after 300 charge-discharge cycles, the LC@CG electrode exhibits the best stability than the LC and LC@C electrodes. This is attributable to the graphene quantum dots, which enhance the morphological stability of the LC@CG electrode during electrochemical measurements. Our findings suggest that LFP-nanocarbon composites are promising as cathode materials and highlight the potential of graphene quantum dots for improving the stability of cathodes.

Entering Voltage Hysteresis in Phase-Separating Materials: Revealing the Electrochemical Signature of the Intraparticle Phase-Separated State

Hysteresis is a general phenomenon regularly observed in various materials. Usually, hysteretic behavior is an intrinsic property that cannot be circumvented in the non-equilibrium operation of the system. Herein, we show that, at least with regard to the hysteretic behavior of phase-separating battery materials, it is possible to enter (deeply) the hysteretic loop at finite battery currents. This newly observed electric response of the electrode, which is inherent to phase-separating materials, is, for the first time, related to its microscopic origin arising from a (significant) share of the active material residing in an intraparticle phase-separated state. This intriguing observation was further generalized by revealing that a phase-separating material can feature (significantly) different chemical potentials at the same bulk lithiation level and temperature when exposed to the same finite current and external voltage hysteresis. Therefore, the intraparticle phase-separated state significantly affected the DC and AC characteristics of the battery. The experimental evidence for entering the intraparticle phase-separated state is supported by thermodynamic reasoning and advanced modeling. The current findings will help advance the understanding, control, diagnostics, and monitoring of batteries composed of phase-separating materials while also providing pertinent motivation for the enhancement of battery design and performance. This article is protected by copyright. All rights reserved.

Design of LiFePO4 and porous carbon composites with excellent High-Rate charging performance for Lithium-Ion secondary battery

Lithium iron phosphate (LFP) is one of the promising cathode materials of lithium ion battery (LIB), but poor electrical conductivity restricts its electrochemical performance. Carbon coating can improve electrical conductivity of LFP without changing its intrinsic property. Uniform coating of carbon on LFP is significant to avoid charge congregation and unpreferable redox reactions. It is the first time to apply the commercial organic binder, Super P® (SP), as carbon source to achieve uniform coating on LFP as cathode material of LIB. The simple and economical mechanofusion method is firstly applied to coat different amounts of SP on LFP. The LIB with the cathode material of optimized SP-coated LFP shows the highest capacity of 165.6 mAh/g at 0.1C and 59.8 mAh/g at 10C, indicating its high capacity and excellent high-rate charge/discharge capability. SP is applied on other commercial LFP materials, M121 and M23, for carbon coating. Enhanced high-rate charge/discharge capabilities are also achieved for LIB with SP-coated M121 and M23 as cathode materials. This new material and technique for carbon coating is verified to be applicable on different LFP materials. This novel carbon coating method is expected to apply on other cathode materials of LIB with outstanding electrochemical performances.

Recycling of cathode from spent lithium iron phosphate batteries

We demonstrate the concept of fabricating new lithium ion batteries from recycled spent 18650 lithium ion batteries (LIB). LiFePO₄ cathode was extracted from these spent LIB using combined approach of pre-treatment, mechanical treatment and hydrometallurgical process wherein weak organic acids, such as methyl sulfonic acid (MSA) and p-toluene sulfonic acid (TSA), were employed for the first time for leaching at room temperature of metal ions instead of conventional strong acids. High leaching efficiencies (95%) were obtained for extraction of Li and Fe using these acids from black mass. Reuse of these extracted metal ions is also demonstrated by precipitating them and synthesizing LiFePO₄ cathode. Structural characterization showed the formation of single-phase LiFePO₄ and electrochemical evaluation of this cathode in a LiFePO₄/Li half-cell exhibited a capacity of 93 mA h/g and 80 mA h/g at 0.2C and 1C rate respectively with good cycle stability.

Data on effect of electrospinning conditions on morphology and effect of heat-treatment temperature on the cycle and rate properties of core-shell LiFePO4/FeS/C composite fibers for use as cathodes in Li-ion batteries

The data in this study are related to the research article "Core-shell electrospun and doped LiFePO₄/FeS/C composite fibers for Li-ion batteries" [1]. Core-shell LiFePO₄/FeS/C composites fiber were prepared via an electrospinning method for use as cathodes in Li-ion batteries. The data presented in this paper showed the effect of electrospinning parameters, including applied voltage, solution flow rate, the concentration of polyvinylpyrrolidone (PVP) (wt%) and a mixed PVP/PEO (polyethylene oxide) (w/w%) polymers on the morphological properties of composites fibers. These data were developed using scanning electron microscopy (SEM). Then, the effect of heat-treatment temperature on fiber morphology was investigated using transmission electron microscopy (TEM). The voltage profile and cycle rate properties of the core-shell LiFePO₄/FeS/C composites obtained after various heat treatments were studied.

Hydrothermal preparation and performance of LiFePO4 by using Li3PO4 recovered from spent cathode scraps as Li source

A novel process recycling Li from the spent LiFePO₄ cathode material has been put forward. The new LiFePO₄ sample is synthesized through hydrothermal reaction by using recovered Li₃PO₄ as Li source and FeSO₄·7H₂O as Fe source. The morphologies, structure and physicochemical properties of the re-synthesized LiFePO₄ cathode material were characterized by Field emission scanning electron microscope (FESEM), X-ray diffraction (XRD), Transmission electron microscope (TEM), X-ray photoelectron spectroscopy (XPS) and electrochemical measurement. The results showed that the morphology and particle size of re-synthesized LiFePO₄ samples become more regular and smaller with the increase of the hydrothermal reaction temperature. Besides, it has been found that the LiFePO₄ cathode material synthesized at 200 °C showed excellent electrochemical properties which deliver a high initial capacity of 144.25 mAh/g at the rate of 1 C and high capacity retention of 96.7% after 200 cycles. Therefore, this work provides a new strategy for recovery and recycle of the spent LiFePO₄ cathode scraps.

Atomic-Scale Observations of (010) LiFePO4 Surfaces Before and After Chemical Delithiation

The ability to view directly the surface structures of battery materials with atomic resolution promises to dramatically improve our understanding of lithium (de)intercalation and related processes. Here we report the use of state-of-the-art scanning transmission electron microscopy techniques to probe the (010) surface of commercially important material LiFePO4 and compare the results with theoretical models. The surface structure is noticeably different depending on whether Li ions are present in the topmost surface layer or not. Li ions are also found to migrate back to surface regions from within the crystal relatively quickly after partial delithiation, demonstrating the facile nature of Li transport in the [010] direction. The results are consistent with phase transformation models involving metastable phase formation and relaxation, providing atomic-level insights into these fundamental processes.

Proposal of a framework for scale-up life cycle inventory: A case of nanofibers for lithium iron phosphate cathode applications

Environmental assessments are crucial for the management of the environmental impacts of a product in a rapidly developing world. The design phase creates opportunities for acting on the environmental issues of products using life cycle assessment (LCA). However, the LCA is hampered by a lack of information originating from distinct scales along the product or technology value chain. Many studies have been undertaken to handle similar problems, but these studies are case-specific and do not analyze the development options in the initial design phase. Thus, systematic studies are needed to determine the possible scaling. Knowledge from such screening studies would open the door for developing new methods that can tackle a given scaling problem. The present article proposes a scale-up procedure that aims to generate a new life cycle inventory (LCI) on a theoretical industrial scale, based on information from laboratory experiments. Three techniques are described to obtain the new LCI. Investigation of a laboratory-scale procedure is discussed to find similar industrial processes as a benchmark for describing a theoretical large-scale production process. Furthermore, LCA was performed on a model system of nanofiber electrospinning for Li-ion battery cathode applications. The LCA results support material developers in identifying promising development pathways. For example, the present study pointed out the significant impacts of dimethylformamide on suspension preparation and the power requirements of distinct electrospinning subprocesses. Nanofiber-containing battery cells had greater environmental impacts than did the reference cell, although they had better electrochemical performance, such as better wettability of the electrode, improving the electrode's electrosorption capacity, and longer expected lifetime. Furthermore, material and energy recovery throughout the production chain could decrease the environmental impacts by 40% to 70%, making the nanofiber a promising battery cathode. Integr Environ Assess Manag 2016;12:465-477. © 2016 SETAC.

Composites of Graphene and LiFePO4 as Cathode Materials for Lithium-Ion Battery: A Mini-review

This mini-review highlights selectively the recent research progress in the composites of LiFePO₄ and graphene. In particularly, the different fabrication protocols, and the electrochemical performance of the composites are summarized in detail. The structural and morphology characters of graphene sheets that may affect the property of the composites are discussed briefly. The possible ongoing researches in area are speculated upon.

Continuous flame aerosol synthesis of carbon-coated nano-LiFePO(4) for Li-ion batteries

Core-shell, nano-sized LiFePO(4)-carbon particles were made in one step by scalable flame aerosol technology at 7 g/h. Core LiFePO(4) particles were made in an enclosed flame spray pyrolysis (FSP) unit and were coated in-situ downstream by auto thermal carbonization (pyrolysis) of swirl-fed C(2)H(2) in an O(2)-controlled atmosphere. The formation of acetylene carbon black (ACB) shell was investigated as a function of the process fuel-oxidant equivalence ratio (EQR). The core-shell morphology was obtained at slightly fuel-rich conditions (1.0<EQR<1.07) whereas segregated ACB and LiFePO(4) particles were formed at fuel-lean conditions (0.8<EQR<1). Post-annealing of core-shell particles in reducing environment (5 vol% H(2) in argon) at 700 °C for up to 4 h established phase pure, monocrystalline LiFePO(4) with a crystal size of 65 nm and 30 wt% ACB content. Uncoated LiFePO(4) or segregated LiFePO(4)-ACB grew to 250 nm at these conditions. Annealing at 800 °C induced carbothermal reduction of LiFePO(4) to Fe(2)P by ACB shell consumption that resulted in cavities between carbon shell and core LiFePO(4) and even slight LiFePO(4) crystal growth but better electrochemical performance. The present carbon-coated LiFePO(4) showed superior cycle stability and higher rate capability than the benchmark, commercially available LiFePO(4).