Proof-of-Concept study of ion-exchange method for the recycling of LiFePO₄ cathode

Recycling spent lithium iron phosphate (LFP) cathodes in an economically sustainable way remains a great challenge due to their low-value elemental composition. Thus, both low-cost technology together with a high-value product are critical for the recovery of the LFP materials. In this study, the commercially mature ion-exchange (IX) method was explored to recover Li from LFP material for the first time. The feasibility of Li-H and Li-K IX reactions using strong and weak acid cation exchange resins was systematically investigated from the thermodynamic and kinetic perspectives. Different organic and inorganic acids were explored to obtain the feeding solution. The IX efficiency was greatly affected by the pH of the feeding solutions. Oxalic acid leaching solution with mild pH value and low iron impurity were determined to be the optimal feeding solution for IX reaction. The kinetics of IX and regeneration reaction were fast, and the resins can be reused several times without loss of IX capacity. Along with the P element remaining in the leaching solution, the Li-K IX reaction delivered a potential product of multi-elemental fertilizer. This simple and economical technology provides a practical recycling strategy for the spent LFP batteries.