UC Develops Eco-Friendly Process to Upgrade Retired LFP Batteries into High-Performance LMFP Material

Engineers at the University of California, San Diego have developed an eco-friendly process that directly converts cathode materials from retired lithium iron phosphate (LFP) batteries into lithium manganese iron phosphate (LMFP)—a superior-performing material. Rather than fully breaking down batteries into their raw components, this method upgrades the material through a structurally compatible intermediate phase, thereby enhancing energy storage capacity. The process begins by disassembling spent battery jelly rolls and immersing the cathode sheets in water. Gentle agitation separates the cathode coating from the aluminum foil, which can then be recovered separately. The reclaimed LFP material is then mixed with salt compounds, ground into a fine powder, and heat-treated. During heating, the salts react to form lithium manganese phosphate (LMP), whose crystal structure closely matches that of LFP, enabling uniform integration of the two phases. As manganese atoms diffuse into the structure and partially replace iron atoms, a single, homogeneous LMFP phase is formed. Simultaneously, a carbon coating develops on the particle surfaces, improving electrical conductivity and enhancing cycling stability. This approach works with end-of-life LFP batteries from various manufacturers and has been validated in both laboratory-scale coin cells and commercially sized pouch cells, with successful scale-up to kilogram quantities. The research team’s next steps involve optimizing process efficiency, yield, and control over material morphology to facilitate industrial adoption. The findings have been published in the journal *Joule*.