Electron beam irradiation for spent LiFePO4 recycling

Efficient recycling of spent lithium-ion batteries (LIBs) is essential for environmental protection and resource sustainability. Direct recycling offers a promising alternative but suffers from difficulty in separating cathode materials from current collectors and low regeneration efficiency. Here, we show a direct recycling strategy for LiFePO 4 (LFP) based on electron beam irradiation (EBI). EBI can selectively degrade the polymer binder, enabling the LFP to be efficiently peeled off from the current collector. The entire peeling process is conducted in a dry, low-temperature environment, avoiding secondary damage to LFP. Furthermore, modulating the electron beam dose allows precise regulation of Li/Fe anti-site defects, promoting a transition of Li + diffusion behavior from one-dimensional (1D) to two-dimensional (2D), thereby significantly enhancing the re-lithiation efficiency and electrochemical performance of the spent LFP. The regenerated LFP shows a discharge capacity of 162 mAh g −1 at 0.1 C and capacity retention of 91.5% after 750 cycles at 0.5 C. This direct recycling strategy offers a scalable, sustainable solution for battery recycling. • Electron beam irradiation selectively degrades the binder, enabling efficient peel-off of LFP from current collectors without secondary damage. • Precise modulation of Li/Fe anti-site defects promotes two-dimensional Li + diffusion, significantly enhancing the re-lithiation kinetics. • The proposed recycling strategy features low energy input and high automation compatibility, demonstrating strong potential for scalable and sustainable industrial application.