Selective leaching and magnetic separation for efficient recovery of lithium and iron phosphate from Aluminum-Contaminated cathode materials of spent LiFePO4 batteries

• Green process for selective Li, Fe recovery from LiFePO 4 with Al impurity control. • Optimized leaching achieves 99.5% Li recovery, leaving Fe and Al in the solid phase. • Magnetic separation yields 99% FePO 4 purity and 97.6% recovery in seven cycles. • Water-based Al removal enhances sustainability and reduces environmental impact. • Economic analysis confirms cost-effectiveness and industrial viability. The recovery and reuse of resources from spent lithium-ion batteries present significant potential for sustainable development and environmental protection. However, challenges remain, particularly in addressing complex issues such as the removal of aluminum (Al) impurities. This paper introduces an efficient and selective process for leaching lithium (Li) from LiFePO 4 cathode material powder, even in the presence of hard-to-remove Al impurities. First, the LiFePO 4 cathode material was separated from damaged Al foil current collectors using an environmentally friendly water stripping method, resulting in the active material powder containing Al impurities. In the subsequent process, a small amount of H 3 PO 4 was used as a leaching agent, H 2 O 2 as an oxidant, and the cathode material was subjected to mechanical activation by ball milling. After continuous optimization of all conditions, an efficient leaching of 99.5 % Li was achieved, with almost all (>99 %) Fe and Al impurities separated as precipitates. Li in the leachate was precipitated as Li 2 CO 3 by adding Na 2 CO 3 at 95 °C, achieving a purity of 99.2 %. A magnetic separation scheme is presented to successfully separate FePO 4 from Al-containing impurities in the leaching residue. After five magnetic separation cycles, the purity of FePO 4 exceeded 98.5 %. Additionally, the mechanisms of the entire reaction system were investigated using characterization methods such as laser particle size analysis, XPS, and XRD. A comprehensive economic evaluation of the entire system confirms its feasibility. This eco-friendly selective separation process shows strong potential for industrial applications and makes a valuable contribution to sustainable development.