使用済みバッテリー廃棄物に対する持続可能ソリューションを前進させる研究（Research Led by Professor Yan Wang Advances Sustainable Solutions for End-of-Life Battery Waste）

2026-05-11ウースター工科大学（WPI）

＜関連情報＞

• https://www.wpi.edu/news/announcements/research-led-professor-yan-wang-advances-sustainable-solutions-end-life-battery-waste
• https://www.cell.com/chem-circularity/fulltext/S3051-2948(26)00016-2

混合正極材料をアップサイクルして高エネルギー密度LiFe 0.75Mn0.25PO 4を製造する Upcycling mixed cathode materials to high-energy-density LiFe0.75Mn0.25PO4

Zifei Meng ∙ Jiahui Hou ∙ Hao Zhou ∙ … ∙ Jianguo Wen ∙ Zhenzhen Yang ∙ Yan Wang

Chem Circularity  Published:May 5, 2026

DOI:https://doi.org/10.1016/j.checir.2026.100020

Graphical abstract

Context & scale

Since the volume of end-of-life batteries is rising rapidly and lithium iron phosphate (LFP) is a leading cathode material, various methods have been developed to recycle LFP. However, conventional recycling routes recover mainly low-value lithium and iron salts. To address this issue, upcycling strategies have been developed. However, existing strategies have yet to achieve both morphology and full elemental recovery under mild ambient conditions, which leads to complex recycling processes and high costs for producing new cathode materials. Thus, we propose a leaching-assisted strategy to upcycle low-value LFP and lithium manganese oxide (LMO) into high-value lithium manganese iron phosphate (LMFP), thus preserving particle morphology while achieving >95% elemental reuse under mild conditions. This strategy illustrates how circularity can be strengthened by upgrading material functionality rather than merely closing elemental loops. Meanwhile, this approach offers clear advantages for scaling. The process avoids high-pressure hydrothermal synthesis and relies on conditions compatible with existing hydrometallurgical infrastructure, thereby reducing barriers to industrial adoption. Techno-economic analysis indicates positive profitability, lower raw material inputs, and reduced energy and wastewater generation compared with conventional recycling, all of which supports alignment with policy objectives related to critical materials security, emissions reduction, and sustainable battery manufacturing. By converting low-value cathodes into next-generation materials, the strategy demonstrates how recycling facilities could evolve into value-generating hubs within circular battery supply chains.

Nevertheless, important challenges remain. Industrial feedstocks are compositionally heterogeneous, and large-scale implementation will require robust impurity management. In addition, the present study focuses on laboratory-scale validation; pilot-scale demonstrations will be needed to quantify environmental benefits across regional supply chains. Future research should also explore integration with battery-sorting systems and partnerships between recyclers, cathode manufacturers, and policymakers to enable deployment across multiple scales. Together, these efforts could help translate cathode upcycling from a promising concept into a core component of circular battery ecosystems.

Highlights

•An upcycling strategy generates high-value LMFP from waste under mild conditions

•More than 95% of waste is reused, which enables near-complete elemental circularity

•Morphology inheritance from LFP to LMFP avoids morphology control processes

•Techno-economic analysis shows positive profitability in various areas

Summary

To address the demand for next-generation cathode materials with high energy density, upcycling LiFePO₄ into LiFe_0.75Mn_0.25PO₄ has attracted considerable attention. Nevertheless, existing strategies have yet to achieve both morphology and full elemental recovery under mild ambient conditions. Here, we report an upcycling route that can address this issue by combining leaching and a high-temperature treatment process. The upcycled LiFe_0.75Mn_0.25PO₄ exhibits enlarged lattice spacing and a high discharge plateau, and it delivers an energy density of 563.7 Wh/kg, 40.3 Wh/kg higher than recycled LiFePO₄, which indicates the high value of the proposed upcycling strategy. At 1 C, LiFe_0.75Mn_0.25PO₄ also exhibits excellent cycling stability of 91% over 700 cycles. Techno-economic analysis also indicates impressive economic and environmental benefits, including 10.4% less raw materials usage and 12.2% less energy consumption and wastewater generation. This work demonstrates a scalable and economic upcycling strategy and provides a promising pathway for sustainable battery upcycling compatible with industrial conditions.