Approach towards the Purification Process of FePO4 Recovered from Waste Lithium-Ion Batteries

The rapid development of new energy vehicles and Lithium-Ion Batteries (LIBs) has significantly mitigated urban air pollution. However, the disposal of spent LIBs presents a considerable threat to the environment. Recycling these waste LIBs not only addresses the environmental issues but also compensates for resource shortages and generates substantial economic benefits. Current recycling processes primarily focus on the extraction of valuable metals, often overlooking the treatment of residual waste post-extraction. This project targets the iron phosphate (FePO4) derived from waste lithium iron phosphate (LFP) battery materials, proposing a direct acid leaching purification process to obtain high-purity iron phosphate. This purified iron phosphate can then be used for the preparation of new LFP battery materials, aiming to establish a complete regeneration cycle that recovers lithium carbonate and iron phosphate from waste LFP materials for the production of LFP. The study investigates process parameters such as acid types and concentrations, leaching time, and the number of leaching cycles. The results demonstrate that, after purification, the levels of impurity metals decrease while the iron content increases correspondingly. Under optimized experimental conditions, the dilute sulfuric acid leaching rates of Al, Cu, Ca, and Ni reached 36.0%, 51.4%, 89.5%, and 90.9%, respectively. Furthermore, hydrothermal treatment in dilute phosphoric acid achieved leaching rates of 87.9%, 85.8%, 98.4%, and 99.1% for Al, Ca, Cu, and Ni, respectively. The microstructure characterization revealed significant changes in phase and grain morphology during the leaching process in dilute phosphoric acid, which are likely associated with the liberation of impurity atoms from the lattice. These findings indicate that acid leaching is highly effective in removing impurities from the iron phosphate recycled from waste LIBs.