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<p>With the rapid increase in retired lithium iron phosphate (LiFePO<sub>4</sub>, LFP) batteries and the rising demand for carbon neutrality, efficient and sustainable recycling of spent LFP cathodes has become a pressing research priority. This review systematically compares three representative recycling approaches—pyrometallurgical, hydrometallurgical, and direct regeneration—highlighting their respective mechanisms, advantages, and limitations. Pyrometallurgy, while industrially mature, suffers from high energy consumption and elemental loss. Hydrometallurgy enables high recovery yields but generates significant chemical waste. In contrast, direct regeneration preserves the cathode structure and offers notable advantages in energy efficiency, environmental impact, and cost-effectiveness. Life cycle assessment results based on the EverBatt model show that direct regeneration significantly reduces greenhouse gas emissions and process costs compared to other methods. Finally, the review outlines current challenges and research directions toward scalable, green, and economically viable LFP recycling technologies.</p>

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Recycling methods for spent lithium iron phosphate cathode materials

  • 期刊论文

  • 发表日期：

    2025年10月30日

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  • Shuaijing Ji,
  • Xiuye Wang,
  • Fengqian Wang,
  • Wuxin Sha,
  • Danpeng Cheng,
  • Zhenxing Wang,
  • Zhongwen Ouyang,
  • Shun Tang,
  • Yuancheng Cao

摘要

With the rapid increase in retired lithium iron phosphate (LiFePO4, LFP) batteries and the rising demand for carbon neutrality, efficient and sustainable recycling of spent LFP cathodes has become a pressing research priority. This review systematically compares three representative recycling approaches—pyrometallurgical, hydrometallurgical, and direct regeneration—highlighting their respective mechanisms, advantages, and limitations. Pyrometallurgy, while industrially mature, suffers from high energy consumption and elemental loss. Hydrometallurgy enables high recovery yields but generates significant chemical waste. In contrast, direct regeneration preserves the cathode structure and offers notable advantages in energy efficiency, environmental impact, and cost-effectiveness. Life cycle assessment results based on the EverBatt model show that direct regeneration significantly reduces greenhouse gas emissions and process costs compared to other methods. Finally, the review outlines current challenges and research directions toward scalable, green, and economically viable LFP recycling technologies.