Rapid Selective Recycling of Spent LiFePO4 Cathodes via a Deep Eutectic Solvent-Assisted Carbothermal Shock Method
Xuhui Zhu1, Hamidreza Arandiyan2, Xue Ma3
1Department of Chemical Engineering, The University of Melbourne, Parkville, VIC 3010, Australia.
ACS Nano
|September 29, 2025
Summary
A novel carbothermal shock process using deep eutectic solvents rapidly recycles lithium iron phosphate (LFP) batteries. This ultrafast method achieves high lithium and iron recovery, creating valuable materials for a circular economy.
Area of Science:
- Materials Science
- Chemical Engineering
- Environmental Science
Background:
- Lithium-ion battery adoption necessitates advanced recycling for lithium iron phosphate (LFP) cathodes.
- Conventional pyrometallurgical recycling of LFP is energy-intensive and inefficient, leading to lithium loss.
Purpose of the Study:
- To develop an ultrafast and efficient recycling process for LFP battery cathodes.
- To overcome the limitations of conventional recycling methods for LFP materials.
Main Methods:
- A carbothermal shock process enhanced by deep eutectic solvents (choline chloride and urea).
- Ultrafast reaction time (∼20 s) with complete encapsulation of LFP by choline chloride to prevent lithium volatilization.
- Magnetic separation for efficient recovery of iron and lithium compounds.
Main Results:
- High recovery efficiencies for lithium (97.39%) and iron (99.17%) as high-purity Fe2P and Li3PO4.
- Elimination of complex separation steps and reduced energy consumption.
- Recovered Fe2P showed enhanced catalytic activity in polyethylene terephthalate plastic alcoholysis.
Conclusions:
- The carbothermal shock process offers an effective and economically viable solution for LFP battery recycling.
- This method promotes a circular economy by enabling high-value resource recovery.
- Synergistic valorization of recycled materials creates new pathways for waste management.
