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Significant attention has focused on olivine-structured LiFePO4 (LFP) as a promising cathode active material (CAM) for lithium-ion batteries. This iron-based compound offers advantages over commonly used Co and Ni due to its lower toxicity abundance, and cost-effectiveness. Despite its current commercial use in energy storage technology, there remains a need for cost-effective production methods to create electrochemically active LiFePO4. Consequently, there is ongoing interest in developing innovative approaches for LiFePO4 production. While LFP batteries exhibit significant thermal stability, cycling performance, and environmental benefits, their growing adoption has increased battery disposal rates. Improper disposal practices for waste LFP batteries result in environmental degradation and the depletion of valuable resources. This review comprehensively examines diverse synthesis approaches for generating LFP powders, encompassing conventional methodologies alongside novel procedures. Furthermore, it conducts an in-depth assessment of the methodologies employed in recycling waste LFP batteries. Moreover, it emphasizes the importance of LFP cathode recycling and investigates pretreatment techniques to enhance understanding. Additionally, it provides valuable insights into the recycling process of used LFP batteries, aiming to raise awareness regarding the market for retired LFP batteries and advocate for the enduring sustainability of lithium-ion batteries.

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Owing to the rapid increase of lithium iron phosphate (LiFePO4) batteries, recycling and regeneration of LiFePO4 enjoys significances for sustainable development and environmental protection. In this study, an effective regeneration method for spent LiFePO4 materials and the influence of Al impurity on the electrochemical performance of regenerated LiFePO4 were studied. Firstly, 99.26% Fe, 99.52% P, 99.58% Li, 59.36% Al and 20.24% Cu in spent LiFePO4 material were leached with 150 g•L-1 H2SO4. Subsequently, Al removal and control were achieved by simply adjusting the pH value, and FePO4•2H2O precursors with different Al contents were prepared. Specially, the LiFePO4 regenerated by FePO4•2H2O precursor containing 0.096% Al exhibits excellent electrochemical performance with discharge capacity of 145 mAh•g-1, 140.5 mAh•g-1 and 130.9 mAh•g-1 at the current density of 1C, 2C and 5C, respectively.

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It is urgent to develop efficient recycling methods for spent LiFePO4 cathodes to cope with the upcoming peak of power battery retirement. Compared with the traditional metallurgical recovery methods that lack satisfactory economic and environmental benefits, the direct regeneration seems to be a promising option at present. However, a simple direct lithium replenishment cannot effectively repair and regenerate the cathodes due to the serious structural damage of the spent LiFePO4. Herein, the spent LiFePO4 cathodes are directly regenerated by a thiourea-assisted solid-phase sintering process. The density functional theory calculation indicates that thiourea has a targeted repair effect on the antisite defects and inactive FePO4 phase in the spent cathode due to the associative priority of amino group (─NH2) in thiourea with Fe ions: Fe3+─N > Fe2+─N. Meanwhile, the pyrolysis products of thiourea can also create an optimal reducing atmosphere and inhibit the agglomeration of particles in the high temperature restoration process. The regenerated LiFePO4 exhibits an excellent electrochemical performance, which is comparable to that of commercial LiFePO4. This targeted restoration has improved the efficiency of direct regeneration, which is expected to achieve large-scale recycling of spent LiFePO4.

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In this study LiFePO4/C composite particles were synthesized using five different carbon sources via a one-step sol-gel method. La-doped LiFePO4 was also synthesized using the sol-gel method. The XRD pattern of LixLayFePO4 (x = 0.9~1.0, y = 0~0.1) after being calcined at 700 °C for 10 h indicates that as the doping ratio increased, the sample's cell volume first increased then decreased, reaching a maximum value of 293.36 Å3 (x = 0.94, y = 0.06). The XRD patterns of Li0.92La0.08FePO4 after being calcined at different temperatures for 10 h indicate that with increasing calcination temperature, the (311) diffraction peak drifted toward a smaller diffraction angle. Similarly, the XRD patterns of Li0.92La0.08FePO4 after being calcined at 700 °C for different durations indicate that with increasing calcination times, the (311) diffraction peak drifted toward a larger diffraction angle. The infrared spectrum pattern of LixLayFePO4 (x = 0.9~1.0, y = 0~0.1) after being calcined at 700 °C for 10 h shows absorption peaks corresponding to the vibrations of the Li-O bond and PO43- group. An SEM analysis of LixLayFePO4 (x = 1, y = 0; x = 0.96, y = 0.04; x = 0.92, y = 0.08) after being calcined at 700 °C for 10 h indicates that the particles were irregular in shape and of uniform size. The hysteresis loops of Li0.92La0.08FePO4 after being calcined at 600 °C, 700 °C, or 800 °C for 10 h indicate that with increasing calcination temperature, the Ms gradually increased, while the Mr and Hc decreased, with minimum values of 0.08 emu/g and 58.21 Oe, respectively. The Mössbauer spectra of LixLayFePO4 (x = 1, y = 0; x = 0.96, y = 0.04; x = 0.92, y = 0.08) after being calcined at 700 °C for 10 h indicate that all samples contained Doublet(1) and Doublet(2) peaks, dominated by Fe2+ compounds. The proportions of Fe2+ were 85.5% (x = 1, y = 0), 89.9% (x = 0.96, y = 0.04), and 96.0% (x = 0.92, y = 0.08). The maximum IS and QS of Doublet(1) for the three samples were 1.224 mm/s and 2.956 mm/s, respectively.

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Lithium iron phosphate (LFP)/graphite batteries have long dominated the energy storage battery market and are anticipated to become the dominant technology in the global power battery market. However, the poor fast-charging capability and low-temperature performance of LFP/graphite batteries seriously hinder their further spread. These limitations are strongly associated with the interfacial Li-ion transport. Here we report a wide-temperature-range ester-based electrolyte that exhibits high ionic conductivity, fast interfacial kinetics and excellent film-forming ability by regulating the anion chemistry of Li salt. The interfacial barrier of the battery is quantitatively unraveled by employing three-electrode system and distribution of relaxation time technique. The superior role of the proposed electrolyte in preventing Li0 plating and sustaining homogeneous and stable interphases are also systematically investigated. The LFP/graphite cells exhibit rechargeability in an ultrawide temperature range of -80°C to 80°C and outstanding fast-charging capability without compromising lifespan. Specially, the practical LFP/graphite pouch cells achieve 80.2% capacity retention after 1200 cycles (2 C) and 10-min charge to 89% (5 C) at 25°C and provides reliable power even at -80°C.

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LiFePO4 is widely used because of its high safety and cycle stability, but its inefficient electronic conductivity combined with sluggish Li+ diffusivity restricts its performance. To overcome this obstacle, applying a layer of conductive carbon onto the surface of LiFePO4 has the greatest improvement in electronic conductivity and Li+ diffusivity. However, the rate performance of carbon-coated LiFePO4 makes it difficult to meet the application requirements. Although nitrogen doping improves electrochemical performance by providing active sites and electronic conductivity, the N-doped carbon coating is prone to agglomeration, which causes a sharp decrease in capacity when the current rate increases. In this work, a synergistic N, Mn codoping strategy is implemented to overcome the aforementioned drawbacks by disrupting the large agglomeration of C-N bonds, improving the uniformity of the surface coating layer to enhance the completeness of the conductive network and increasing the number of Li+ diffusion channels, and thus accelerating the mass transfer rate under high-rate current. Consequently, this strategy effectively improves the rate capability (119 mA h g-1 at 10 C) while maintaining excellent cycling performance (88% capacity retention over 600 cycles at 5 C). This work improves the rate of ion diffusion and the rate capability of micrometer-sized LiFePO4, thus, enabling its wider application.

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The rapid proliferation of power sources equipped with lithium-ion batteries poses significant challenges in terms of post-scrap recycling and environmental impacts, necessitating urgent attention to the development of sustainable solutions. The cathode direct regeneration technologies present an optimal solution for the disposal of degraded cathodes, aiming to non-destructively re-lithiate and straightforwardly reuse degraded cathode materials with reasonable profits and excellent efficiency. Herein, a potential-regulated strategy is proposed for the direct recycling of degraded LiFePO4 cathodes, utilizing low-cost Na2SO3 as a reductant with lower redox potential in the alkaline systems. The aqueous re-lithiation approach, as a viable alternative, not only enables the re-lithiation of degraded cathode while ignoring variation in Li loss among different feedstocks but also utilizes the rapid sintering process to restore the cathode microstructure with desirable stoichiometry and crystallinity. The regenerated LiFePO4 exhibits enhanced electrochemical performance with a capacity of 144 mA h g-1 at 1 C and a high retention of 98% after 500 cycles at 5 C. Furthermore, this present work offers considerable prospects for the industrial implementation of directly recycled materials from lithium-ion batteries, resulting in improved economic benefits compared to conventional leaching methods.

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In Li-ion batteries, the origin of memory effect in Al-doped Li4Ti5O12 has been revealed as the reversible Al-ion switching between 8a and 16c sites in the spinel structure, but it is still not clear about that for olivine LiFePO4, which is one of the most important cathode materials. In this work, a series of Na-doped and Ti-doped LiFePO4 are prepared in a high-temperature solid-state method, electrochemically investigated in Li-ion batteries and characterized by X-Ray Diffraction (XRD), Fourier Transform Infrared Spectroscopy (FTIR) and Magic-Angle-Spinning Nuclear Magnetic Resonance (MAS NMR). Compared with non-doped LiFePO4, the Ti doping can simultaneously suppress the memory effect and the Li-Fe anti-site, while they are simultaneously enhanced by the Na doping. Meanwhile, the Ti doping improves the electrochemical performance of LiFePO4, opposite to the Na doping. Accordingly, a schematic diagram of phase transition is proposed to interpret the memory effect of LiFePO4, in which the memory effect is attributed to the defect of Li-Fe anti-site.

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The performance of Li-ion batteries (LIBs) at sub-ambient temperatures is limited by the resistive interphases due to electrolyte decomposition, particularly on the anode surface. In this study, lithium fluorosulfonate (LFS) was added to commercial electrolytes to enhance the low-temperature electrochemical performance of LiFePO4 (LFP)/graphite (Gr) pouch cells. The addition of LFS significantly reduced the charge transfer resistance of the anode, substantially extending the cycle life and discharge capacity of commercial LFP/Gr pouch cells at -10 and -30 °C. Compared with the capacity retention rate of the baseline electrolyte at -10 °C (80 % after 25cycles), the capacity retention rate of the LFS electrolyte after 100 cycles under 0.5 C/0.5 C was retained at 94 %. Further mechanistic studies showed that the LFS additive induced the formation of a solid electrolyte interphase (SEI) film comprising inorganic-rich LiF, Li2SO4, and additional organic fluorides and sulfides to maintain good stability at the Gr/electrolyte interface during low-temperature operation. LFS suppressed electrolyte decomposition by forming a robust and low-resistance SEI film on the anode. These results demonstrate that LFS is a promising electrolyte additive for low-temperature LFP/Gr pouch cells.

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Spent ternary lithium-ion batteries contain abundant lithium resource, and their proper disposal is conducive to environmental protection and the comprehensive utilization of resources. Separating valuable metals in the ternary leaching solution is the key to ensuring resource recovery. However, the traditional post-lithium extraction strategies, which heavily rely on ion exchange to remove transition metal ions in the leachate, encounter challenges in achieving satisfactory lithium yields and purities. Based on this, this paper proposed a new strategy to prioritize lithium extraction from ternary leachate using "(+) LiFePO4/FePO4 (-)" lithium extraction system. The preferential recovery of lithium can be realized by controlling the potential over 0.1 V versus Standard Hydrogen Electrode (SHE) without introducing any impurity ions. The lithium recovery rate reaches 98.91%, while the rejection rate of transition ions exceeds 99%, and the separation coefficients of lithium to transition metal ions can reach 126. Notably, the resulting lithium-rich liquid can directly prepare lithium carbonate with a purity of 99.36%. It provides a green and efficient strategy for the preferential recovery of lithium from the spent ternary leachate.

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Lithium iron phosphate batteries, known for their durability, safety, and cost-efficiency, have become essential in new energy applications. However, their widespread use has highlighted the urgency of battery recycling. Inadequate management could lead to resource waste and environmental harm. Traditional recycling methods, like hydrometallurgy and pyrometallurgy, are complex and energy-intensive, resulting in high costs. To address these challenges, this study introduces a novel low-temperature liquid-phase method for regenerating lithium iron phosphate positive electrode materials. By using N2H4·H2O as a reducing agent, missing Li+ ions are replenished, and anti-site defects are reduced through annealing. This process restores nearly all missing Li+ ions at 80 °C/6h. After high-temperature sintering at 700 °C/2h, the regenerated LiFePO4 matches commercial LiFePO4 in terms of anti-site defects and exhibits excellent performance with a 97 % capacity retention rate after 100 cycles at 1C. Compared to high-temperature techniques, this low-temperature liquid-phase method is simpler, safer, and more energy-efficient, offering a blueprint for reclaiming discarded LiFePO4 and similar materials.

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Low temperature has been a major challenge for lithium-ion batteries to maintain satisfied electrochemical performance, as it leads to poor rechargeability and low capacity retention. Traditional carbonate solvents, vinyl carbonate and dimethyl carbonate are indispensable components of commercial electrolytes. However, the higher melting point of these carbonate solvents causes their electrical conductivity to be easily reduced when temperatures drop below zero, limiting their ability to facilitate lithium ion transport. In this work, we demonstrate that the use of methyl propionate (MP) carboxylate and fluorocarbonate vinyl (FEC) electrolytes can overcome the limitations of low temperature cycling. Compared with carbonate electrolyte, MP has the characteristics of low melting point, low viscosity and low binding energy with Li+, which is crucial to improve the low temperature performance of the battery, while FEC is an effective component to inhibit the side reaction between MP and lithium metal. The carefully formulated MP-based electrolyte can generate a solid electrolyte interface with low resistance and rich in inorganic substances, which is conducive to the smooth diffusion of Li+, allowing the battery to successfully cycle at a high rate of 0.5 C at -20 °C, and giving it a reversible capacity retention rate of 65.3% at -40oC. This work designs a promising advanced electrolyte and holds the potential to overcome limitations of lithium-ion batteries in harsh conditions.

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To mitigate the environmental impact of the improper disposal of spent LiFePO4 batteries and reduce resource waste, the development of LiFePO4 recycling technologies is of paramount importance. Meanwhile, olivine-structured NaFePO4 in sodium-ion batteries has received great attention, due to its high theoretical specific capacity of 154 mAh g-1 and excellent stability. However, olivine NaFePO4 only can be synthesized from olivine LiFePO4. Accordingly, in this proposal, developing the continuous flow electrochemical solid-liquid reactor-based metal ion insertion technology is to utilize the olivine FePO4, recycled from LiFePO4, and to synthesize NaFePO4. Additionally, by employing I- as the reducing agent, NaFePO4 is successfully synthesized with a discharge-specific capacity of 134 mAh g-1 at 0.1C and a remarkable capacity retention rate of 86.5% after 100 cycles at 0.2C. And the reasons for sodium deficiency in the synthesized NFP are elucidated through first-principles calculations. Furthermore, the kinetics of the solid-solution reaction 2 (Na2/3+ßPO4→ Na1-αFePO4) mechanism improve with cycling and are sensitive to temperature. Utilizing a minimal amount of reducing agent in the electrochemical reactor, NaFePO4 synthesis is successfully achieved. This innovative approach offers a new, cost-effective, and environmentally friendly strategy for preparing NaFePO4 from recycling LiFePO4.

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Lithium carboxymethyl cellulose (CMC-Li) is a promising novel water-based binder for lithium-ion batteries. The direct synthesis of CMC-Li was innovatively developed using abundant wood dissolving pulp materials from hardwood (HW) and softwood (SW). The resulting CMC-Li-HW and CMC-Li-SW binders possessed a suitable degree of substitutions and excellent molecular weight distributions with an appropriate quantity of long- and short-chain celluloses, which facilitated the construction of a reinforced concrete-like bonding system. When used as cathode binders in LiFePO4 batteries, they uniformly coated and dispersed the electrode materials, formed a compact and stable conductive network with high mechanical strength and showed sufficient lithium replenishment. The prepared LiFePO4 batteries exhibited good mechanical stability, low charge transfer impedance, high initial discharge capacity (∼180 mAh/g), high initial Coulombic efficiency (99 %), excellent cycling performance (<3% loss over 200 cycles) and good rate capability, thereby outperforming CMC-Na and the widely used cathode binder polyvinylidene fluoride.

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In this study, a flexible, free-standing Fe-doped CoP nanoarrays electrode for superior lithium-ion storage has been successfully fabricated. The electrode combines the advantages of a Fe-doping and a flexible carbon cloth (CC) support, resulting in a high specific capacity (1356 mAh/g at 0.2 A/g) and excellent cycling stability (1138 mAh/g after 100 cycles). The cyclic voltammetry (CV) curves at different scan rates investigate the outstanding lithium storage behavior of Fe-CoP-NAs/CC which indicates a combined influence of diffusion behavior and capacitance behavior on the electrochemical process. The galvanostatic intermittent titration technique (GITT) analyzes the diffusion kinetics of Li+ which indicates the fast diffusion kinetics in the Fe-CoP/NAs/CC anode. The assembled Fe-CoP-NAs/CC//LiFePO4 battery exhibits a remarkable capacity of 325.2 mAh/g even at 5 A/g. And the battery also has good cycle stability, and still provides 498.1 mAh/g specific capacity after 200 cycles. Moreover, the Fe-CoP-NAs/CC//LiFePO4 soft-pack battery can continuously power the LEDs when it is bent at various angles which demonstrates its potential for use in wearable devices.

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Reduction of the environmental impact, energy efficiency and optimization of material resources are basic aspects in the design and sizing of a battery. The objective of this study was to identify and characterize the environmental impact associated with the life cycle of a 7.47 Wh 18,650 cylindrical single-cell LiFePO4 battery. Life cycle assessment (LCA), the SimaPro 9.1 software package, the Ecoinvent 3.5 database and the ReCiPe 2016 impact assessment method were used for this purpose. Environmental impacts were modelled and quantified using the dual midpoint-endpoint approach and the "cradle-to-gate" model. The results showed the electrodes to be the battery components with the highest environmental impact (41.36% of the total), with the negative electrode being the most unfavourable (29.8 mPt). The ageing, calibration and testing process (53.97 mPt) accounts for 97.21% of the total impact associated with the production process's consumption of energy, and 41.20% of the total impact associated with the battery. This new knowledge will allow a more detailed view of the environmental impact of cylindrical cell LiFePO4 batteries, favouring the identification of critical points to enhance their sustainable production.

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Lithium iron phosphate (LiFePO4, LFP), an olivine-type cathode material, represents a highly suitable cathode option for lithium-ion batteries that is widely applied in electric vehicles and renewable energy storage systems. This work employed the ball milling technique to synthesize LiFePO4/carbon (LFP/C) composites and investigated the effects of various doping elements, including F, Mn, Nb, and Mg, on the electrochemical behavior of LFP/C composite cathodes. Our comprehensive work indicates that optimized F doping could improve the discharge capacity of the LFP/C composites at high rates, achieving 113.7 mAh g-1 at 10 C. Rational Nb doping boosted the cycling stability and improved the capacity retention rate (above 96.1% after 100 cycles at 0.2 C). The designed Mn doping escalated the discharge capacity of the LFP/C composite under a low temperature of -15 °C (101.2 mAh g-1 at 0.2 C). By optimizing the doping elements and levels, the role of doping as a modification method on the diverse properties of LFP/C cathode materials was effectively explored.

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The low ionic conductivities of aprotic electrolytes hinder the development of extreme fast charging technologies and applications at low temperatures for lithium-ion batteries (LIBs). Herein, we present an electrolyte with LiFSI in acetone (DMK). In DMK electrolytes, the solvation number is three, and solvent-separated ion pairs (SSIPs) are the dominant structure, which is largely different from other linear aprotic electrolytes where salts primarily exist as contact ion pairs (CIPs). With incompact solvation structures due to the weak solvation ability of DMK with Li+, the ionic conductivity reaches 45 mS/cm at room temperature. The percentage of SSIPs increases as temperatures decrease in DMK electrolytes, which is totally different from the carbonate-based electrolytes but greatly beneficial to low-temperature ionic conductivity. With the appropriate addition of VC and FEC, DMK-based electrolytes still exhibit a superhigh ionic conductivity. Even at -40 °C, the ionic conductivity is greater than 10 mS/cm. With DMK-based electrolytes, LIBs with thick LiFePO4 electrodes can be cycled at high rates and at low temperatures.

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The energy stability and electronic structural of graphene and defective graphene oxide (GO) parallel to the surface of LiFePO4 (010) were theoretically investigated by using first-principles density functional theory calculations within the DFT + U framework. The calculated formation energy shows that GO coating on the surface of LiFePO4 (010) is energetically favorable and has higher bond strength compared to graphene. The calculation of the electronic structure indicates that the emergence of band in-gap states originates from graphene coating, with adsorbed O atoms contributing significantly above the Fermi level. Electron density difference indicate that GO stands on the LFP (010) surface through C-O and Fe-O bonds, rather than relying on van der Waals forces placed parallel to the LFP crystal, with the chemical bond at the LFP/GO interface (Fe-O-C) both anchoring the coated carbon layer and promoting electron conductivity at the interface. In addition, LFP/GO shows superior electrochemical performance, Atomic Populations suggests that the average Fe-O bonding on the surface of LiFePO4 (010) was clearly changed after graphene or GO coating, which led to the expansion of Li+ channels and favored the migration insertion and extraction of Li+.

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Composite polymer electrolytes are systems of choice for future solid-state lithium metal batteries (LMBs). Poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP) is among the most interesting matrices to develop new generation quasi-solid electrolytes (QSEs). Here it is reported on nanocomposites made of PVDF-HFP and pegylated SiO2 nanoparticles. Silica-based hybrid nanofillers are obtained by grafting chains of poly(ethylene glycol) methyl ether (PEG) with different molecular weight on the surface of silica nanoparticles. The functionalized nanofiller improves the mechanical, transport and electrochemical properties of the QSEs, which show good ionic conductivity values and high resistance against dendrite penetration, ensuring boosted long and safe device operation. The most promising result is obtained by dispersing 5 wt% of SiO2 functionalized with short PEG chains (PEG750, Mw = 750 g mol-1) in the PVDF-HFP matrix with an ease solvent-casting procedure. It shows ionic conductivity of 0.1 mS cm-1 at 25 °C, more than 250 h resistance to stripping/plating, and impressive results during cycling tests in LMB with LiFePO4 cathode.