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Recycling Lithium Iron Phosphate Batteries: Investigation of
Fine Particle Flotation Using Flocculants
Anna Vanderbruggen
Université de Lorraine, GeoRessources, France
Aliza Marie Salces
Université de Lorraine, GeoRessources, France
Helmholtz Zentrum Dresden Rossendorf, Helmholtz Institute Freiberg for Resource Technology, Germany
Martin Rudolph
Helmholtz Zentrum Dresden Rossendorf, Helmholtz Institute Freiberg for Resource Technology, Germany
Chiedza Nzuma
Norwegian University of Science and Technology, Trondheim, Norway
ABSTRACT: Lithium iron phosphate (LFP) batteries are gaining prominence in the growing EV market due its
long life cycle, cost-effectiveness, and safety. Consequently, its influx in the battery waste stream is anticipated,
which necessitates a tailored recycling process. Froth flotation is a promising technique to separate the cathode
and anode active material of black mass from lithium-ion batteries before downstream recycling processes.
However, unlike previously studied chemistries (e.g., NMC, LCO), LFP presents a more intricate challenge
due to its fine particle sizes (d10–d90 of 0.5–6.0 µm), rendering them susceptible to entrainment and thereby
affecting float fraction recovery. In this work, the effective separation of LFP black mass into graphite-rich and
LiFePO4-rich fraction was investigated by implementing a flocculant, polyacrylamide (PAM). Initial results
reveal improved selectivity with the use of flocculants in model black mass (pristine and liberated particles of
LFP and graphite) flotation. However, complexities arise when PAM was employed in an industrially pyrolyzed
black mass, impacting flotation performance and material recovery dynamics.
INTRODUCTION
Lithium-ion batteries (LIBs) are at the forefront of mod-
ern rechargeable energy storage technologies, exten-
sively employed in portable electronics, electric vehicles,
and renewable energy systems. Characterized by their
high energy density and extended cycle life, LIBs oper-
ate by leveraging lithium ions for effective energy storage
and discharge. A diverse range of LIB types exists, each
characterized by distinct cathode chemistries, including
LiNiMnCoO2 (NMC), LiCoO2 (LCO), and LiFePO4 (
LFP), among others. This variety underscores the versatility
and adaptability of LIBs to various applications and per-
formance specifications. Among these, LFP batteries have
garnered significant attention across industries, attributed
to their superior safety, longevity, and cost-efficiency. With
the growing demand for LFP batteries, the development
Recycling Lithium Iron Phosphate Batteries: Investigation of
Fine Particle Flotation Using Flocculants
Anna Vanderbruggen
Université de Lorraine, GeoRessources, France
Aliza Marie Salces
Université de Lorraine, GeoRessources, France
Helmholtz Zentrum Dresden Rossendorf, Helmholtz Institute Freiberg for Resource Technology, Germany
Martin Rudolph
Helmholtz Zentrum Dresden Rossendorf, Helmholtz Institute Freiberg for Resource Technology, Germany
Chiedza Nzuma
Norwegian University of Science and Technology, Trondheim, Norway
ABSTRACT: Lithium iron phosphate (LFP) batteries are gaining prominence in the growing EV market due its
long life cycle, cost-effectiveness, and safety. Consequently, its influx in the battery waste stream is anticipated,
which necessitates a tailored recycling process. Froth flotation is a promising technique to separate the cathode
and anode active material of black mass from lithium-ion batteries before downstream recycling processes.
However, unlike previously studied chemistries (e.g., NMC, LCO), LFP presents a more intricate challenge
due to its fine particle sizes (d10–d90 of 0.5–6.0 µm), rendering them susceptible to entrainment and thereby
affecting float fraction recovery. In this work, the effective separation of LFP black mass into graphite-rich and
LiFePO4-rich fraction was investigated by implementing a flocculant, polyacrylamide (PAM). Initial results
reveal improved selectivity with the use of flocculants in model black mass (pristine and liberated particles of
LFP and graphite) flotation. However, complexities arise when PAM was employed in an industrially pyrolyzed
black mass, impacting flotation performance and material recovery dynamics.
INTRODUCTION
Lithium-ion batteries (LIBs) are at the forefront of mod-
ern rechargeable energy storage technologies, exten-
sively employed in portable electronics, electric vehicles,
and renewable energy systems. Characterized by their
high energy density and extended cycle life, LIBs oper-
ate by leveraging lithium ions for effective energy storage
and discharge. A diverse range of LIB types exists, each
characterized by distinct cathode chemistries, including
LiNiMnCoO2 (NMC), LiCoO2 (LCO), and LiFePO4 (
LFP), among others. This variety underscores the versatility
and adaptability of LIBs to various applications and per-
formance specifications. Among these, LFP batteries have
garnered significant attention across industries, attributed
to their superior safety, longevity, and cost-efficiency. With
the growing demand for LFP batteries, the development