Fluidized bed homogeneous crystallization recovery of high purity Lithium phosphate from industrial wastewater

Abstract

The growing demand for lithium-ion batteries has intensified the need for efficient, scalable, and sustainable lithium recovery technologies. In this study a fluidized bed homogeneous crystallization recovery (FBHC) system for the selective recovery of lithium from cathode manufacturing wastewater was developed. The recovered pellets were in the form of high-purity lithium phosphate. A comprehensive parametric investigation was conducted to identify the optimal operating conditions of initial lithium concentration, effluent pH, surface loading rate, temperature, and phosphate-to-lithium molar ratio. Packing the bed with homogenous lithium phosphate seeds reduced the time to equilibrium from hundreds of hours to minutes. The optimal conditions of bed height and particle size of the seeds were also surveyed. Under the optimized conditions, the FBHC process achieved a total lithium recovery of ~92%, a crystallization ratio of ~90%, and a product purity of ~98%. The obtained recovered Li₃PO₄ was composed of dense, spherical granules with mechanically stable structures. Compared with other recovery technologies, the FBHC system provides superior control over nucleation and growth kinetics with no formation of hazardous sludge, and requires no use of organic solvents or membranes. The FBHC process demonstrates profitability for the recovery of lithium from real industrial wastewater in a robust and environmentally benign manner, which aligns well with the principles of a circular economy.

Graphical abstract

Keywords

Lithium recovery / Real industrial wastewater / Granulation mechanisms / Recovery Optimization / Packed bed of seeds / Cost/revenue analysis

Highlight

	● An FBHC system was developed for the recovery of lithium from industrial wastewater.
	● High efficiencies (91.85% for Li+, 80% for PO43–) were achieved for high-purity pellets (98.20%).
	● Insights of operational parameters and recovery mechanisms were explored.
	● Packing the bed with homogenous lithium phosphate seeds drastically reduced the reaction time.
	● Cost/Revenue analysis demonstrated profitability of the FBHC process.

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