Geochemistry-Driven Recovery of Li and Fe From Spent LiFePO₄ Cathodes via Stabilized Phosphorus Mineralization

Abstract

The rapid expansion of lithium iron phosphate (LFP) batteries presents a critical challenge for sustainable end-of-life management, where conventional recycling methods heavily depend on intensive acid/oxidant use and overlook persistent phosphorus pollution. Herein, we propose a geochemistry-guided mineral stabilization strategy that enables acid- and oxidant-free extraction of valuable metals and a simultaneous phosphorus fixation process from spent LFP cathodes. By exploring CaCl₂ as a mineralization promoter, phosphorus is selectively immobilized into the stable mineral Goryainovite (Ca₂PO₄Cl) with a fixation efficiency exceeding 99.9%, thereby preventing aqueous phosphorus release at the source. Simultaneously, lithium and iron are efficiently extracted as soluble chlorides and subsequently recovered as high-grade Li₂CO₃ and Fe₂O₃ with yields above 90% through stepwise precipitation. This work establishes a transformative paradigm that integrates geochemical stabilization principles with sustainable resource recovery, offering an environmentally benign pathway for the valorization of spent batteries and other phosphorus-bearing wastes.

Keywords

geochemistry mineralization / Goryainovite / green chemistry / phosphorus contamination control / spent LiFePO₄ recycling

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