Recycling Process Research Articles

Increasing thermostability of the key photorespiratory enzyme glycerate 3‐kinase by structure‐based recombination

SummaryAs global temperatures rise, improving crop yields will require enhancing the thermotolerance of crops. One approach for improving thermotolerance is using bioengineering to increase the thermostability of enzymes catalysing essential biological processes. Photorespiration is an essential recycling process in plants that is integral to photosynthesis and crop growth. The enzymes of photorespiration are targets for enhancing plant thermotolerance as this pathway limits carbon fixation at elevated temperatures. We explored the effects of temperature on the activity of the photorespiratory enzyme glycerate kinase (GLYK) from various organisms and the homologue from the thermophilic alga Cyanidioschyzon merolae was more thermotolerant than those from mesophilic plants, including Arabidopsis thaliana. To understand enzyme features underlying the thermotolerance of C. merolae GLYK (CmGLYK), we performed molecular dynamics simulations using AlphaFold‐predicted structures, which revealed greater movement of loop regions of mesophilic plant GLYKs at higher temperatures compared to CmGLYK. Based on these simulations, hybrid proteins were produced and analysed. These hybrid enzymes contained loop regions from CmGLYK replacing the most mobile corresponding loops of AtGLYK. Two of these hybrid enzymes had enhanced thermostability, with melting temperatures increased by 6 °C. One hybrid with three grafted loops maintained higher activity at elevated temperatures. Whilst this hybrid enzyme exhibited enhanced thermostability and a similar Km for ATP compared to AtGLYK, its Km for glycerate increased threefold. This study demonstrates that molecular dynamics simulation‐guided structure‐based recombination offers a promising strategy for enhancing the thermostability of other plant enzymes with possible application to increasing the thermotolerance of plants under warming climates.

Influence of Process Conditions During Aqueous and Direct Recycling of NMC811 Cathodes.

This study investigated the impact of various process conditions on the aqueous, direct recycling of LiNi0.8Mn0.1Co0.1O2 (NMC811) cathodes. Three model systems were used. The first system assumes that the current collector delamination is performed in a dry environment without the use of water as a process medium. Consequently, the NMC811 is only exposed to water during classification, where no aluminum foil is present. The second model system assumes that the current collector delamination occurs in water. Therefore, the NMC811 is exposed to water in the presence of aluminum foil. Due to the pH increase caused by the Li+/H+ exchange reaction, the pH value surpasses the stability window of the aluminum-oxide passivation layer (pH 4.5-8.5), resulting in the deposition of aluminum-containing species on the NMC811 surface. The third model system is identical to the second, with the exception that H3PO4 is added. This causes the pH to decrease and prevents corrosion of the aluminum foil. The findings reveal that process conditions significantly affect the surface chemistry on NMC811, influencing electrochemical performance. Notably, aluminum-containing species increase polarization. Heat treatment simulating regeneration led to cation mixing as surface species diffused into the NMC811 bulk structure, highlighting the need to control recycling process conditions.

Experimental and multiscale analysis of volume fraction effects in tensile properties of recycled PLA-PDA/kenaf fiber 3D printing filament composites

Polylactic acid, a biodegradable thermoplastic derived from renewable sources, has notable environmental advantages and versatile properties. However, recycled PLA often experiences reduced mechanical strength and altered chemical composition due to the recycling process, limiting its suitability for 3D printing filament applications. Recognizing the inherent limitations of recycled PLA (rPLA), this research employs a unique method of coating rPLA with dopamine (DA) and reinforcing it with kenaf fibers (KF) at various weight fractions, introducing a novel multiscale modeling approach to address the challenges of interfacial bonding and tensile performance in recycled polymers. The methodology integrates experimental single filament tensile testing with multiscale finite element modeling to accurately predict the composite’s mechanical behavior across different scales. The findings reveal that a 5% kenaf fiber weight/volume fraction provides the optimal balance between tensile strength, stiffness, and toughness, achieving a significant 49.3% improvement over the unreinforced rPLA. However, increasing the kenaf fiber content beyond 5% leads to a decline in mechanical properties, attributed to higher fiber agglomeration and suboptimal fiber-matrix interactions. The novelty of this research lies in its combined use of PDA coating, natural kenaf fiber reinforcement, and advanced multiscale modeling to enhance and predict the performance of rPLA-PDA/kenaf composites, paving the way for sustainable, high-performance materials in 3D printing applications.

Recycling Li-Ion Batteries via the Re-Synthesis Route: Improving the Process Sustainability by Using Lithium Iron Phosphate (LFP) Scraps as Reducing Agents in the Leaching Operation

The development of hydrometallurgical recycling processes for lithium-ion batteries is challenged by the heterogeneity of the electrode powders recovered from end-of-life batteries via physical methods. These electrode materials, known as black mass, vary in composition, containing differing amounts of nickel, manganese, and cobalt (NMC), as well as other chemicals, such as lithium iron phosphate (LFP). This study presents the results of the hydrometallurgical treatment of mixed NMC and LFP black masses aimed at creating flexible recycling processes. This approach leverages the reducing power of LFP to optimize the leach liquor composition for re-synthesizing NMC precursors. In particular, the leaching conditions were optimized based on the LFP content in the solid feed to maximize the extraction of key metals (Ni, Mn, Co, and Li). The leaching solid residue, graphite, was treated and characterized as a secondary raw material for new anode preparation. Iron phosphate was recovered by increasing the pH of the leach liquor, and the NMC precursors were obtained via coprecipitation. This process achieved a recycling rate of 51%, based on the black mass input and the mass of recovered elements in the output products. Additionally, substituting LFP scraps as the reducing agent in place of H2O2 reduced the recycling process’s environmental impact by avoiding 1.7 tons of CO2-equivalent emissions per ton of NMC black mass.

Evaluation of Performance Improvement Rate of Plastic Production System Using ARENA: A Case Study of Phoenix Plastic Services

Production improvement has become essential to all industrial activity because of the fierce competition among today's production systems and organizations and the unquenchable customer demand. The shorter product life cycle has significantly increased the demand for prompt reactions to increase the productivity and efficiency of these industrial systems. This study examined the evaluation of performance improvement rate of plastic production system using ARENA. The report provided by the plastics industry was used in the study to analyze and assess the rate of performance improvement of the plastic manufacturing system. The location of the bottleneck was determined by the research following a thorough analysis of the plastic company's data, which included information on all manufacturing lines and procedures. The research employed Arena to assess and compute the rate of improvement in system performance while accounting for the material transporting process throughout the production line. The conveyor velocity maintains a lock at 75m/min, despite the company's report stating that the transports run at 30m/min. The optimized and unoptimized processes when obtained from a finished recycling process running for 1000 working hours, indicate that the conveyor process had 1045 and 1027 entity input and output, respectively, and the transporter process had 953 and 929 entities input and output respectively. The remaining number left when considering the number that enters the system with the number that leaves the system went to waste, resulting from the sorting and demagnetization process. The introduction of the conveyor brings 10.549% in the production rate and 50% decrease on expenses spent in labor. Through the conveyor system's speed control factor, which is an automated procedure, the system's percentage increment may be further raised. By raising the conveyor system's speed, more items will be produced. Conveyor system installation free up more space for additional production-related equipment, increasing products formed and the company's profit. The cost of purchasing and installing the conveyor will be covered by the excess profit.

Simulation study on heavy metals, phthalate esters, and organic halogens: Content and distribution characteristics during waste paper recycling.

Imported waste paper and recycled pulp may contain pollutants, posing potential environmental risks to the ecosystem of China. This study examined the presence and distribution patterns of heavy metals, phthalate esters (PAEs), and adsorbable organic halogens (AOX) in recycled pulp and production wastewater after various recycling processes of three typical restricted types of imported waste paper. The results indicated that the concentration ranges of heavy metals, PAEs, and AOX in the three types of imported recycled waste paper were 21.61-40.38mg/kg, 15.35-27.88mg/kg, and 19.21-57.72mg/kg, respectively. The comparative analysis with the initial waste paper demonstrated a reduction in heavy metal content in the recycled pulp by 17.80-49.75%, PAEs by 65.42-90.55%, and AOX by 32.80-42.34%. The average concentrations of these pollutants in wastewater were 0.85-1.66mg/L, 27.28-59.86mg/L, and 1.15-3.34mg/L, respectively. Chromium and lead were identified as the primary heavy metals present in the waste paper. Following pulping, No. 1 and No. 2 met the arsenic and lead levels specified in the "Reuse Fiber Pulp" standard (GB/T24320-2021), whereas No. 3 met these criteria after de-inking only. The main PAEs detected in the waste paper were dibutyl phthalate and di(2-ethylhexyl) phthalate, most of which were removed during the pulping stage. Significantly higher levels of AOX were observed in No. 2 and No. 3 than in No. 1, with a minimal impact on AOX removal from the pulp during the recycling process.

Circular Economy and Chemical Conversion for Polyester Wastes.

Polyester waste in the environment threatens public health and environmental ecosystems. Chemical recycling of polyester waste offers a dual solution to ensure resource sustainability and ecological restoration. This minireview highlights the traditional recycling methods and novel recycling strategies of polyester plastics. The conventional strategy includes pyrolysis, carbonation, and solvolysis of polyesters for degradation and recycling. Furthermore, the review delves into exploring emerging technologies including hydrogenolysis, electrocatalysis, photothermal, photoreforming, and enzymatic for upcycling polyesters. It emphasizes the selectivity of products during the polyester conversion process and elucidates conversion pathways. More importantly, the separation and purification of the products, the life cycle assessment, and the economic analysis of the overall recycling process are essential for evaluating the environmental and economic viability of chemical recycling of waste polyester plastics. Finally, the review offers perspective into the future challenges and developments of chemical recycling in the polyester economy.

Vegetation Greening Promoted the Precipitation Recycling Process in Xinjiang

Under the combined influences of climate and vegetation change, land–atmosphere interactions have enhanced, and precipitation recycling is an important part of this. Previous studies of the precipitation recycling process have focused on calculating the precipitation recycling rate (PRR) and analyzing the influencing factors. However, the climate-driven and vegetation-induced precipitation recycling process variations were not quantified. This study has systematically examined the precipitation recycling process in a typical arid region using the Eltahir and Bras model, random forest algorithm, and partial least-squares structural equation modeling. During 1982–2018, the leaf area index (LAI) and evapotranspiration (ET) rate both increased significantly, with growth rates of 0.06 m2m−2/decade and 13.99 mm/decade, respectively. At the same time, the average PRR in Xinjiang was 13.92% and experienced significant growth at a rate of 1.28%/decade. The climate-driven and vegetation-induced PRR variations were quantified, which contributed 79.12% and 20.88%, respectively. In addition, the positive effects of both of these on PRR variations through ET did not increase with the increase in ET, but rather decreased sharply and then stabilized. This study can provide favorable theoretical support for mitigating the contradiction in water use and balancing economic development and ecological security by quantifying the regulation of precipitation by vegetation.

Fire parameters of recycled plastic pellets

AbstractDuring the recycling process, waste plastic undergoes various processes that change its geometry. The thermal properties and fire behaviour of plastic in different geometries has not been widely studied. This paper aims to determine critical thermal properties of plastic pellets made of recycled plastic. For this paper, cone calorimeter tests of various volumes of recycled plastic pellets of low‐ and high‐density polyethylene and polypropylene were conducted. During these tests, the heat release rate (HRR), mass loss rate and time‐to‐ignition were measured, thereafter the heat of combustion (HOC) was calculated. A calibration of suitable time‐to‐ignition equations is carried out. The average HRR is between 353 and 581 kW/m2 with an external heat flux of 50 kW/m2. The measured time‐to‐ignition values ranged between 27 s at 50 kW/m2 and just more than 90 s at 25 kW/m2. Values obtained analytically from the thermally thin time‐to‐ignition equations for these materials describe ignition well, which appears to be due to the particulate nature of the samples. The HOC (40–41 MJ/kg) shows good agreement with the HOC for virgin plastic found in literature. These properties can be used as a basis for material characterisation, and further testing will be done before using this as simulation inputs to determine how bulk stored plastic pellets will behave in the event of a fire.

Dewatering and Transport in Sustainable Sediment Management: A Review

This paper deals with the dewatering and handling of dredged sediments in the context of sustainability and renewability of natural resources. Dewatering is a critical part of sediment management, as the high water content of dredged sediments becomes a challenge for transportation, final storage and/or recycling. This is why it is necessary to reduce their water content before transportation. Conventional methods suggest using land-based drained basins, which is a sustainable solution. However, this solution has certain drawbacks: dewatering the sediment is time-consuming and involves the use of large land areas. The main problem with this method of dewatering can be solved by proposing mechanical dewatering in the vicinity of the dredging operation. Once the sediment has been sufficiently dewatered, it should be shoveled and transported again. The proposed paper covers the study of the dewatering and shoveling ability of sediments. After introducing why dewatering is a critical phase in the recycling process of sediment, some techniques for dewatering large volumes of high-water sediments are briefly reported. Typical dewatering laboratory tests are detailed, demonstrating their usefulness for understanding the mechanisms of natural dewatering. A laboratory dewatering press machine is reported and the procedure used for a sediment sludge. The last section concerns a recent innovative test implemented for the study of the shoveling ability and adhesion of sediments. This study improves our understanding of the phenomenon of sediment dewatering, for both natural and mechanical dewatering. It also provides the protocols for typical laboratory tests on sediment dewatering and shoveling ability.

Geochemical evidence for terrigenous sediment recycling in the Late Permian subcontinental lithospheric mantle of the northern North China Craton

Understanding the recycling process of subducted slab in subduction zones is vital to deciphering the heterogeneity of cratonic mantle and the variable compositions of continental arc igneous rocks. This study presents a comprehensive analysis of zircon U-Pb ages, Hf-O isotopes, hornblende major elements, whole-rock major and trace elements, as well as Sr-Nd-Hf isotopes of mafic igneous rocks from the northern North China Craton. These data constrain metasomatic processes in the cratonic mantle. The Late Permian mafic igneous rocks (ca. 254−252 Ma) studied are characterized by arc-like trace element signatures and enriched whole-rock Sr-Nd-Hf isotopes, with (87Sr/86Sr)i ratios of 0.7063−0.7076, εNd(t) values of −18.0 to −9.3, and εHf(t) values of −29.7 to +0.5. In addition, they also have elevated zircon δ18O values of 5.9‰−7.0‰, and variable zircon εHf(t) values of −19.4 to +6.0. These features suggest the rocks were derived from an enriched mantle with the involvement of terrigenous sediments. We propose that the subcontinental lithospheric mantle of the northern North China Craton was mainly metasomatized by terrigenous sediment-derived hydrous melt during the southward subduction of the Paleo-Asian Ocean. Moreover, partial melting of the metasomatic mantle may be triggered by the slab rollback related to the closure of the Paleo-Asian Ocean in the Late Permian, which resulted in the formation of the mafic igneous rocks studied. Thus, the Late Permian igneous rocks studied provide petrological and geochemical evidence of the crust-mantle interaction during the subduction of the Paleo-Asian Ocean.

Oxygen diffusion effects in thermo-oxidative degradation of typical tire rubber

Thermo-oxidative degradation of tire rubber has been demonstrated as a green method for upcycling waste tire rubber. However, the complicated tire compositions present challenges to achieving the homogeneity and efficiency of the reclaimed products, which restricts their widespread industrial adoption. To address this challenge, natural rubber(NR)and natural rubber/butadiene rubber(NR/BR)were innovatively designed to simulate complex tire compositions and investigate the influence of oxygen diffusion on thermo-oxidative degradation at 150–240 °C. The evolution of chemical structural changes and mechanical properties during degradation was traced by FTIR, UV–vis, and nanoindentation test. A basic reactive-diffusion model based on Fickian oxygen diffusion was used to simulate the diffusion profiles. It was found that recrosslinking decreases the oxygen permeability coefficient during NR/BR degradation as the temperature increases, making it difficult for oxygen to diffuse into the inner layer, and therefore tire rubber degrades unevenly. Lower temperatures and prolonged treatment times were recommended to enhance degradation. These findings provide substantial guidance for optimizing the recycling process of tire rubber and its sustainable utilization.

System analysis with life cycle assessment for NiMH battery recycling.

The nickel metal hydride (NiMH) battery technology has been designed for use in electric vehicles, solar-powered applications and power tools. These batteries contain the critical and strategic raw materials cobalt, nickel and several rare earth elements (REE). When designing a battery recycling process, there are several choices to be made regarding end-products and process chemicals. The aim of this study is to investigate and compare the environmental and economic sustainability of different recycling options for NiMH batteries by taking projected market developments into consideration and by applying life cycle assessment and life cycle costing methods. The comparative study is limited to recovery of the REEs. Two hydrometallurgical processes for recovery of the REEs from the anode material are compared with extraction of REEs from primary sources in China. The processes compared are a high-temperature sulfation roasting process and a process based on hydrochloric acid leaching followed by precipitation of REE oxalates. By comparing the different recycling approaches, the hydrochloric acid process performs best. However, the use of oxalic acid has a large impact on the overall sustainability footprint. For the sulfation roasting process, the energy, sodium hydroxide and sulphuric acid consumption contribute most to the total environmental footprint. This article is part of the discussion meeting issue 'Sustainable metals: science and systems'.

Recycled graphite enabled superior performance for lithium ion batteries

Recycling graphite attracts growing attention since cumulative amount of spent Li-ion batteries and the shortage of graphite supply chain. Although various recycling methods have been reported, the recycled graphite cannot reach the strict commercial standards of purity, scalability, efficiency, and capacity, preventing it from battery manufacturing. Herein, the important roles of defects and functional groups on the graphite surface are deeply studied, and a closed-loop graphite recycling process with the surface recovery and modification for the graphite from the end-of-life batteries is demonstrated. The recovered graphite delivers a purity of over 99.9 % and an average initial coulombic efficiency of 91.5 %. Compared with commercial graphite in industrial standard battery testing parameters, full cells with recovered graphite possess enhanced rate reversibility, doubled cycle life, over 10 % higher capacity along with half anode material cost. These impressive results not only underscore the transformative potential of surface reconstruction and modification in graphite recycling, but also present economic feasibility and sustainable pathway for significantly improving battery performance and addressing global resource challenges via integration with the hydrometallurgical recycling process.

Innovative strategies for ammonia nitrogen removal in rare earth tailings: An advanced element recycling process using leaching, chemical precipitation and adsorption

Residual ammonium salt in closed rare earth mining sites leads to elevated levels of ammonia nitrogen in the surrounding environment. To mitigate ammonia nitrogen pollution at its source, a cost-effective and environmentally friendly recycling process was proposed. This process involves leaching residual ammonia nitrogen using a magnesium sulfate solution, followed by chemical precipitation for ammonia nitrogen removal. Additionally, nitrogen can be recovered as ammonia gas through the thermal decomposition of precipitates, allowing for further ammonia nitrogen adsorption from the leachate. The residual ammonium salts leaching rate reached 96.38 % with a 0.1 mol/L magnesium sulfate solution at a flow rate of 0.6 mL/min. The chemical precipitation method achieved a maximum nitrogen removal rate of 86.87 %, with an activation energy of 2.6 kJ/mol, indicating a relatively rapid process. At 190 °C, the ammonia nitrogen release rate of precipitates was 82.5 % after 2 h of thermal decomposition. The adsorption process was consistent with pseudo-second-order kinetics models using thermal decomposition products. Overall, the comprehensive removal rate of residual ammonium salts from the closed rare earth mining site was approximately 83.3 % in recycling process, optimizing the utilization of phosphorus, magnesium, and nitrogen and achieving efficient and environmentally friendly nitrogen removal.

Evaluating the sustainability of a pilot-scale spent lithium-ion battery recycling process

This study presents a sustainability analysis of a pilot-scale process, integrating multiple technologies, designed to recover strategic metals from spent lithium-ion batteries (LIBs). The modularity of the proposed processes allows for a focused sustainability analysis of each technology as part of the overall recycling process, allowing for efficient evaluation and comparison of individual steps. The ESCAPE approach combines simplicity and reproducibility of inventory, providing sufficient resolution to better evaluate the benefits and drawbacks of battery recycling options across various process categories. The results show that positive ESCAPE index values for lithium (Li) and cobalt (Co) are obtained. However, negative values are found for nickel (Ni) and manganese (Mn). The study also evaluates the differences in the sustainability of the proposed pilot across some European countries, accounting for variations in electrical energy mixes and material production footprints relevant to the considered regions. Results indicate that the proposed pilot plant has the potential to support a sustainable LIB value chain.

Phosphorus bioavailability and recycling potential in various organic Wastes: Assessment by enzymatic hydrolysis and 31P NMR

Phosphorus(P) recycling from waste streams is crucial to mitigate the P depletion crisis. P forms and contents in organic waste are critical for determining the recycling method and efficiency. We constructed an approach to characterize P forms in seven organic waste by combining chemical sequential extraction, enzymatic hydrolysis, and nuclear magnetic resonance(NMR). Livestock manure and straw exhibited a higher active P(H2O-P&NaHCO3-P)(70.54%-84.40% and 65.78%-85.26% of total P) than sewage sludge(18.22%) and food waste(43.90%). Enzymatic hydrolysis revealed over 10% P in the so-called active P of corn(11.30%) and rice straw(13.32%) was phytate-like P, which is not bioavailable. These findings indicate the chemical sequential extraction inaccurately gauges bioavailable-P and underscores the need to convert phytate into plant-available P in recycling processes(biogas, composting), especially for crop straws and chicken manure. This work introduces a novel methodological framework for assessing P potential bioavailability in organic waste, providing fundamental knowledge for the P recycling process optimization.

Production of calcium and magnesium titanates using concentrated solar energy

Solar energy is an adequate technology for different processes in metallurgy, materials processing, recycling, or ceramic-refractory materials, because of the high temperatures attained which are reached when the solar radiation is concentrated. This growing interest has also emerged from the obtaining of such temperatures without releasing pollutants such as carbon dioxide, SOx, NOx, or dioxins. Other benefits associated with concentrated solar energy are that this energy source is virtually free and the possibility of operating in places isolated from the electrical grid. Therefore, this research proposes the integration of concentrated solar energy in the production of calcium and magnesium titanates, which are materials with increasing demand in the field of electric components. Experimental work was carried out in the Odeillo solar furnace located in Font-Romeu-Odeillo-Via (France) using a 1.5-meter parabolic concentrator and mixtures of CaO and TiO2 and MgO and TiO2 in 1:1 molar ratio. Mixtures were subjected to values of incident radiation exceeding 900 W/m2 without using any special atmosphere and in very short times, which did not surpass 10 minutes. X-ray diffraction technique was employed to confirm the formation of the CaTiO3 and MgTiO3 perovskites. Therefore, concentrated solar energy might be a novel, fast, and environmentally sustainable manner of producing calcium and magnesium titanates.

Formation of aluminum nitride in dross by contact-diffusion reaction during aluminum recycling

Secondary aluminum dross is a solid waste after aluminum extraction from the slag produced during aluminum recycling. It is classified as a hazardous waste due to the high content of active aluminum nitride (AlN). This work studied the thermodynamics and kinetics of AlN formation in aluminum dross. Aluminum tends to react with N2 to form AlN, when the partial pressure of nitrogen (N2) is much greater than that of oxygen (O2) (PN2≫PO2) in thermodynamics. Additionally, the reaction between aluminum and N2 is accelerated with the increasing temperature. Approximately 36.37% of aluminum was transformed into AlN at 700°C according to kinetic analysis. Aluminum recycling involves smelting, refining, and dross processing. The dross produced from these different processes has various compositions and hazardous properties. The formation mechanism of AlN from the three processes was revealed based on the thermodynamic and kinetic analyses. The reaction mechanisms in these processes were identified as surface contact reaction, internal and surface contact reaction, and rotational surface contact reaction between the aluminum melt and N2, respectively. X-ray diffraction (XRD) and electron probe microanalysis (EPMA) analyses were used to determine the phase and composition of the aluminum dross. The nitrogen content in the aluminum dross from smelting, refining, and dross processing was found to be 3.3%, 5.2%, and 9.6%, respectively. The monthly dross production were 276.3 tons, 22.7 tons, and 318.2 tons, respectively, according to statistics. It was calculated that the nitrogen generated in the three process was 9.12 tons, 1.18 tons, and 20.25 tons, respectively. Therefore, dross processing is the primary source of AlN. A rapid dross processing method with small-scale vertical stirring was proposed to shorten the reaction between the aluminum melt and N2, thereby reducing AlN formation. This work could provide guidance for reducing hazardous AlN in aluminum dross and optimizing the aluminum recycling process.

From waste to material strategy: A closed-loop regeneration process of spent LiFePO4 batteries

A closed-loop regeneration route to recover valuable elements from spent LiFePO4 batteries is proposed. After hot-acid leaching, the leaching rates of Li, Fe and P are above 99.8 %, and the graphite powder retain in the residue with grade of 93.33 %. With iron powder cementation, 99.96 % Cu is removed from acid leaching solution to obtain sponge copper. And then 96.67 %Al and 89.30 %F are precipitated in the form of AlPO4(s) and FeF3(s) at pH = 3.75. Li, Fe and P within the purified solution are prepared as LiFePO4 precursors by co-precipitation method, and finally LiFePO4/C materials are synthesized after two-stage calcination. The recycled LiFePO4/C materials demonstrate excellent electrochemical performance with a discharge capacity of 153.1 mAh·g−1 at 0.1C and a capacity retention of 94.0 % after 500 cycles at 1C. The present recycling process provides a strategy for short and efficient regeneration of spent LiFePO4 batteries.