Orthorhombic LiFePO4 (LFP) offers highly reversible
redox reactions, making it an attractive cathodic material for lithium-ion
batteries. This electrochemical property was exploited to develop
an environmentally benign selective lithium extraction process based
on CO2 and hydrogen peroxide that can be applied to direct
LFP recycling. The proof of concept of this green delithiation process
was demonstrated in a previously published paper, while the process
optimization and the establishment of the reaction kinetic mechanism
are addressed in the current paper. First, the effects of solid to
liquid ratio (S/L), temperature, CO2 pressure, and initial
H2O2 to LFP molar ratio were studied through
an orthogonal design of experiments. In the range of conditions studied
and considering the objective of maximizing the S/L ratio, the optimal
conditions are a temperature of 20 °C, a CO2 pressure
of 2 atm, and a H2O2 to LFP molar ratio of 1.25.
In addition, reaction kinetic models were used to determine the reaction
mechanism. The activation energies obtained based on rate constants
from shrinking core and Avrami models are 15.7 and 13.9 kJ mol–1, respectively. While these values reveal a mixed
or diffusion-controlled heterogeneous reaction, the analysis of half-delithiated
LFP particles under scanning–transmission electron microscopy
revealed the reaction being controlled by nucleation rather than diffusion.
In this context, the Avrami model that accounts for nucleation and
growth in solid-state reactions proved the most appropriate. Further,
the reaction mechanism is concluded to be limited by nucleation of
FP phase within the body of LFP during the early reaction stage and
to sequentially shift to the one-dimensional diffusion-limited crystallite
growth regime. Finally, it is shown that CO2 acts as a
buffering agent by neutralizing the LiOH formed by Fenton-like reactions
between H2O2 and ferric iron in LFP.