Mechanical methods for materials concentration of lithium iron phosphate (LFP) cells and product potential evaluation...

The production and sales of lithium-ion batteries (LIB) are rapidly expanding nowadays, causing a significant impact on the consumption of critical raw materials, such as lithium. Thus, developing and improving methods for the separation and recovery of materials from LIBs is necessary to ensure the supply of critical raw materials, as well as to meet the recycling targets set by some countries. This study evaluated and compared two mechanical routes to concentrate materials of LiFePO₄ (LPF) cells. In addition, the economic, environmental, and scarcity risk potential of the products obtained through the best mechanical route were evaluated. The first route involved 6 grinding cycles in a knife mill, followed by particle size separation into 3 fractions. The second route involved a single grinding cycle (knife and hammer mill were tested), followed by particle size separation into 6 fractions. The second route showed more promise, with obtaining fractions rich in (1) iron, (2) aluminum and copper, and (3) cathode materials. Additionally, less operating time and energy consumption were necessary. The hammer mill offered a better separation for the iron and the cathodic materials (LiFePO₄), while the knife mill proved to be more effective in concentrating the aluminum and copper. The product potential evaluation of the best route revealed that the priority fractions for recycling in economic and environmental assessment in LFP2 are 2 < n < 9.5 mm (due Cu and Al) and n < 0.5 mm (due Li). Considering the scarcity risk, priority should be assigned to the recycling of the fraction n < 0.5 due to lithium.