Chen\u2019s research group had previously developed a method to restore old LFP batteries to fresh LFP material. But the recycled batteries kept the same chemistry as before.<\/p>\n
\u201cAfter regeneration, it was still LFP,\u201d Li said. The new method upgrades the material to LMFP, which can store more energy. \u201cThis could offer a more valuable end use for spent batteries,\u201d Chen added.<\/p>\n
Turning used cathodes into a better material<\/p>\n
The recycling<\/a> process begins by opening the battery packs and taking out the tightly rolled layers inside, known as a jelly roll. Researchers cut these layers into sheets, soak them in water, and gently shake the material to separate the cathode<\/a> coating from the aluminum foil.<\/p>\n \u201cThe aluminum foil can also be recycled separately,\u201d Li explained.<\/p>\n The remaining cathode material is dried and ground into a fine black powder. Researchers then add lithium, manganese, and phosphate salts to provide the ingredients for LMFP.<\/p>\n The team ran into a big challenge because the added salts and the original LFP material have different crystal structures.<\/p>\n \u201cTheir structures are incompatible,\u201d Li revealed. \u201cIf mixed directly, the atomic distribution of the end product will not be uniform and will have worse electrochemical performance.\u201d<\/p>\n To fix this, the researchers first prepare an intermediate compound, lithium manganese phosphate (LMP), with a crystal structure similar to LFP. They finely grind and mix the powder, then heat it. \u201cThis is where the exciting chemistry happens,\u201d Chen said.<\/p>\n As the powder is heated, LMP forms first and mixes evenly with the LFP. Manganese atoms slowly take the place of some iron, creating a uniform LMFP structure. A thin layer of carbon also forms around each particle, helping the material conduct electricity and protecting it during many charging cycles.<\/p>\n Results show promise for large-scale battery recycling<\/p>\n The upgraded LMFP material stored more energy than the original LFP and kept its durability and safety. Researchers tested the method using LFP batteries from different manufacturers and scaled up the process to kilogram quantities.<\/p>\n The recycled material also worked well in both small lab coin cells and larger pouch cells, which are similar to the batteries<\/a> used in electric vehicles and large energy storage systems.<\/p>\n The research team now plans to make the process more efficient and get more material from it. They also want to improve the material\u2019s composition and structure to boost performance and prepare the technology for large-scale recycling.<\/p>\n![\"\"](\"https:\/\/www.newsbeep.com\/uk\/wp-content\/uploads\/2026\/07\/1783151962_757_image.png\" "\\"New")
How spent cathode material is recovered from an end-of-life LFP battery. Left to right: the battery pack\u2019s contents are unrolled, cut into smaller sheets, soaked in water, and stirred. Image credit: University of California San Diego<\/a><\/p>\n