Recycling of metals from LiFePO4 battery cathode material by using ionic liquid based-aqueous biphasic systems

Lithium-ion batteries are essential for electric vehicles and energy storage devices. With the increasing demand for their production and the concomitant surge in waste generation, the need for an efficient and environmentally friendly recycling process has become imperative. This work presents a new approach for recycling of metals from the LiFePO4 (LFP) cathode material. The cathode material was first leached by a HCl solution without an oxidizing agent. Subsequently, an ionic-liquid-based aqueous biphasic system (IL-based ABS) was used for the separation of lithium and iron from leachate solutions, followed by a precipitation process. The influence of the acid concentration, solid-to-liquid ratio and leaching time on the leaching yield was investigated. UV-vis absorption spectra revealed the presence of mixed-valent iron in the leachate, with 83 +/- 1% Fe(II) and 17 +/- 1% Fe(III). The ABS systems comprised tributyltetradecylphosphonium chloride [P-44414]Cl and a salting-out agent (HCl or NaCl). The extraction percentage of iron reached 90% and less than 1% of lithium was extracted under the studied optimal conditions. Further enhancement of iron extraction, reaching 98%, was achieved via a two-stage cross-current extraction process. Iron was precipitated from the loaded IL phase with an efficiency of 97% as Fe(OH)(2) and Fe(OH)(3), using an aqueous ammonia solution. Lithium was precipitated as Li3PO4 with a lithium purity of 99.5% by adding K3PO4 solution. The ionic liquid used in the process was efficiently regenerated and used in four extraction cycles with no activity decline, with an extraction percentage of 90% of iron in each cycle.