Nonferrous impurities such as Cu, Zn, and Co, along with inert materials such as gangue and silica in pyrite cinder (PyC), significantly limit its direct use as an iron source for battery-grade ferric phosphate (FP) or lithium iron phosphate (LFP). To address this issue, a new process using alkali excitation, mechanical activation, and aging to remove impurities from PyC was developed. Additionally, a novel method for preparing carbon-coated lithium iron phosphate (LFP@C) using purified PyC (p-PyC) as the iron source was explored. With 20% NaOH, 3h of ball milling activation, and aging at 200 ℃ for 4h, the Fe content in PyC increased to 55.14%, with a recovery rate of 95.43%. Compared with those in untreated PyC, the Fe leaching rate in p-PyC reached 98.25%, and the levels of Al, Cu, Zn, Co, and Si in the acid-leaching liquor were reduced by 96.62%, 96.67%, 99.85%, 75.96%, and 99.99%, respectively. The LFP@C cathode material was directly prepared via carbothermal reduction using acid-leaching liquor from p-PyC as the iron source. The LFP@C-30% crystal particles were well connected, and the surface was effectively coated with a carbon layer to form a conductive layer. At 0.1C, the specific capacity was 159.09 mAh·g−1, with 95.63% capacity retention after 100 cycles. LFP@C-30% presented the lowest charge transfer resistance and an apparent diffusion coefficient (DLi) of 2.33×10−11 cm2·s−1. This study offers a simple and effective method for removing impurities from PyC and presents a new approach for converting PyC into high-demand FPs or LFPs.
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