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    基于无酸浸出的废磷酸铁锂电池中锂的选择性回收

    Selective Lithium Recovery from Spent Lithium Iron Phosphate Batteries via Acid-Free Leaching

    • 摘要: 为应对新能源汽车产业高速发展带来的锂离子电池规模化退役与资源化处理挑战,本研究针对废磷酸铁锂电池黑粉成分复杂、回收流程长的问题,开发了基于过硫酸钠的无酸浸出策略,实现了锂的选择性回收与正极材料的短流程再生。在常温条件下,该工艺通过调控浸出时间(40 min)、磷酸铁锂/过硫酸钠摩尔比(2.0∶1.2)及固液比(50 g/L)等关键参数,可从成分复杂的黑粉中优先浸出锂,同时可有效降低铁、铜、铝等杂质的溶出。机理分析表明,该过程通过LiFePO4向FePO4的转变实现锂的选择性脱出,而不破坏颗粒结构。浸出液经除杂、沉淀获得碳酸锂,通过碳热还原法再合成磷酸铁锂正极材料。再生材料的结构、形貌及表面碳包覆特性与商用材料相当,其在0.1 C倍率下放电比容量超过155 mA·h/g,0.5 C循环100次后容量保持率达99.2%。本研究提出的温和、短流程浸出−再生策略,为从成分复杂的实际电池黑粉中直接、高效回收锂并再生高性能正极材料提供了可行的工艺路径,具有良好的工业化应用前景。

       

      Abstract: Currently, the electric vehicle industry is expanding rapidly, leading to challenges in the large-scale retirement and resource recovery of lithium-ion batteries. The black mass from spent LiFePO4 batteries has a complex composition. In this study, an acid-free leaching process based on sodium persulfate was developed to treat the black mass. This method achieves selective lithium recovery and enables cathode material regeneration. Key parameters were optimized via single-factor experiments. At ambient temperature, lithium was selectively leached from the complex black mass by adjusting the leaching time to 40 min, the LiFePO4/Na2S2O8 molar ratio to 2.0:1.2, and the solid-liquid ratio to 50 g/L. A lithium leaching efficiency of 86.4% was achieved, while the dissolution of Fe, Cu, and Al was minimized. Notably, temperatures above 35 °C led to a substantial increase in the leaching rates of Cu and Al, and temperatures ≥65 °C promoted the dissolution of Fe. Therefore, ambient temperature operation saves energy and ensures leaching selectivity. The mechanism was investigated using multiple characterization techniques. X-ray diffraction (XRD) revealed that the majority of LiFePO4 was converted into FePO4, following the reaction: 2LiFePO4 + Na2S2O8 → 2FePO4 + Li2SO4 + Na2SO4. Fourier transform infrared spectroscopy (FTIR) showed characteristic peak shifts and a new peak corresponding to the bending vibration of the PO4 3− group. Scanning electron microscopy (SEM) images demonstrated that the graphite and LiFePO4 particle structures were preserved after leaching, confirming the mildness of the process. Based on the shrinking-core model, the incomplete lithium leaching was attributed to in-situ retained FePO4, which obstructed the contact between Na2S2O8 and internal LiFePO4. After impurity removal and leachate concentration, lithium was precipitated using a saturated Na2CO3 solution. High-purity Li2CO3 was obtained through purification. Regenerated LiFePO4 (RLFP) was prepared via carbothermal reduction using recycled Li2CO3 and FePO4 as raw materials, with 20% glucose added as the carbon source, followed by roasting at 700 °C for 10 h under an N2 atmosphere. RLFP exhibited properties comparable to those of commercial LiFePO4 (CLFP): XRD confirmed its standard crystal phase; X-ray photoelectron spectroscopy (XPS) verified that Fe was in the Fe2+ valence state; and Raman spectroscopy showed distinct D and G peaks with an ID/IG ratio < 1, indicating a high degree of graphitization. Electrochemical tests demonstrated that RLFP delivered a specific discharge capacity exceeding 155 mAh/g at 0.1 C and maintained a capacity retention of 99.2% after 100 charge-discharge cycles at 0.5 C. Our mild, acid-free, short-flow leaching and regeneration strategy enables efficient selective lithium recovery from black mass and the regeneration of high-performance LiFePO4. This work offers a practical pathway for the recycling of spent LiFePO4 batteries and demonstrates promising potential for industrial-scale applications.

       

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