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<p>Iron phosphate (FePO₄) is a critical precursor for lithium iron phosphate (LiFePO₄) cathode materials in electric vehicle batteries. This study explores the precipitation behavior of FePO<sub>4</sub>·2H<sub>2</sub>O from sulfate leach solutions containing Fe, Ni, and Co, simulating pregnant leaching solutions from ferronickel (FeNi) powder leaching in sulfuric acid. A 2<sup>4</sup> factorial design was employed to examine the effects of pH, temperature, P/Fe molar ratio, and seed addition on Fe precipitation and coprecipitations of Ni and Co. Higher pH, P/Fe ratio, and seed dosage promoted Fe precipitation but also increased Ni and Co co-precipitations, whereas elevated temperature enhanced Fe precipitation while suppressing Ni and Co incorporation. Screening results identified pH, temperature, and P/Fe ratio as the dominant factors, which were further optimized by Response Surface Methodology. The optimum conditions—pH 1.68, 35&#xa0;°C, P/Fe ratio of 1, and no seed addition—yielded 93.65% Fe precipitation with 23.78% Fe content in the precipitate, alongside limited Ni (2.95% precipitation; 1.05% in solid) and no detectable Co. Despite high Fe recovery, the product’s purity and particle characteristics remain below battery-grade requirements, highlighting the need for additional Fe purification (e.g., solvent extraction in chloride media) prior to iron precipitation. The findings of this study provide fundamental insights into the precipitation behavior of FePO₄ toward producing battery-grade FePO₄, enabling the co-production of FePO₄ and NiSO₄ from FeNi alloy leachates and advancing the integrated utilization of laterite-derived alloys for electric vehicle (EV) battery material development.</p>

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Optimization of FePO4 precipitation from laterite-derived Fe–Ni–Co sulfate solutions for lithium iron phosphate cathode applications

  • 期刊论文

  • 发表日期：

    2026年5月30日

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  • Putu Ade Sitha Suaryanti,
  • Gabriella Esther Dameria Prasetyo,
  • Anisa Surya Wijareni,
  • Zela Tanlega Ichlas,
  • Wahyudin Prawira Minwal,
  • Mohammad Zaki Mubarok

摘要

Iron phosphate (FePO₄) is a critical precursor for lithium iron phosphate (LiFePO₄) cathode materials in electric vehicle batteries. This study explores the precipitation behavior of FePO4·2H2O from sulfate leach solutions containing Fe, Ni, and Co, simulating pregnant leaching solutions from ferronickel (FeNi) powder leaching in sulfuric acid. A 24 factorial design was employed to examine the effects of pH, temperature, P/Fe molar ratio, and seed addition on Fe precipitation and coprecipitations of Ni and Co. Higher pH, P/Fe ratio, and seed dosage promoted Fe precipitation but also increased Ni and Co co-precipitations, whereas elevated temperature enhanced Fe precipitation while suppressing Ni and Co incorporation. Screening results identified pH, temperature, and P/Fe ratio as the dominant factors, which were further optimized by Response Surface Methodology. The optimum conditions—pH 1.68, 35 °C, P/Fe ratio of 1, and no seed addition—yielded 93.65% Fe precipitation with 23.78% Fe content in the precipitate, alongside limited Ni (2.95% precipitation; 1.05% in solid) and no detectable Co. Despite high Fe recovery, the product’s purity and particle characteristics remain below battery-grade requirements, highlighting the need for additional Fe purification (e.g., solvent extraction in chloride media) prior to iron precipitation. The findings of this study provide fundamental insights into the precipitation behavior of FePO₄ toward producing battery-grade FePO₄, enabling the co-production of FePO₄ and NiSO₄ from FeNi alloy leachates and advancing the integrated utilization of laterite-derived alloys for electric vehicle (EV) battery material development.