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May 10, 2026Energy & environment materials1 citationsOpen Access

Sustainable Revival of Spent Lithium Iron Phosphate Cathodes in Li‐Ion Batteries: Recycling and Surface Engineering Approaches

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YHYan HeRWRuigang Wang

Key Points

  • This review aims to evaluate advancements in recycling lithium iron phosphate catehodes and enhancing their performance through surface engineering.
  • Systematic examination of hydrometallurgical, pyrometallurgical, and direct recycling methods.
  • Analysis of thermodynamic and kinetic characteristics of lithium recovery pathways.
  • Critical evaluation of surface modification strategies, including coatings for enhanced electrical performance.
  • Hydrometallurgy achieves lithium recovery efficiencies between 95-99%.
  • Regenerated LFP materials reach capacities of 140-160 mAh g−1, comparable to commercial LFP.
  • Economic and environmental assessments indicate industrial feasibility for recycled LFP materials.

Abstract

This review systematically examines recent advancements and ongoing challenges in the recycling of lithium iron phosphate (LFP) cathode materials, including hydrometallurgical, pyrometallurgical, and direct recycling approaches. Thermodynamic and kinetic characteristics, lithium recovery mechanisms, and lithium recovery pathways of each method are critically analyzed. Recent studies of hydrometallurgy presented high lithium recovery efficiencies approaching 95–99%. Regenerated LFP species have been investigated recently to reach 140–160 mAh g −1 in capacity that are very close to commercial LFP cathode materials. A comparative evaluation of their economic value and environmental effects is also conducted to examine their industrial feasibility. It also discusses surface engineering and modification strategies after recycling, including carbon, polymer, and metal/metal oxide coatings, aiming at restoring or then enhancing the electrochemical performance of regenerated LFP by boosting the electron conductivity and Li diffusion. By integrating insights from recycling technologies and materials engineering, this review offers a holistic outlook on transforming spent LFP into high‐performance cathode materials, thereby providing valuable guidance for sustainable battery development and circular economy initiatives.

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Cite This Study

He et al. (2026) studied this question.

synapsesocial.com/papers/6a002222c8f74e3340f9d096https://doi.org/10.1002/eem2.70390
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