Sustainable Utilization of Fe(Ⅲ) Isolated from Laterite Hydrochloric Acid Lixivium Via Ultrasonic-Assisted Precipitation to Synthesize LiFePO4/C for Batteries.

Ultrasonic-assisted precipitation was employed to sustainably isolate Fe in the hydrochloric acid lixivium of low-grade laterite for the synthesis of battery-grade iron phosphate. The recovery efficiency of Ni and Co exceeded 99%, while the removal efficiency of the Fe impurity reached a maximum of 95%. Precipitation parameters for the selective isolation of Fe (MgO precipitant, pH 1, 70–80 °C) were optimized and used in ultrasonic precipitation experiments. The use of ultrasonic waves in the precipitation process enhanced micromixing by reducing the size of primary grains and mitigating particle agglomeration, thereby significantly improving the purity of the isolated compound and providing high-quality iron phosphate (FePO4·2H2O). The LiFePO4/C composite prepared from as-precipitated FePO4 exhibited excellent electrochemical performance, with a discharge capacity of 149.7 mAh/g at 0.1 C and 136.3 mAh/g at 0.5 C after 100 cycles, retaining almost 100% cycling efficiency. This novel and facile method for iron removal from laterite acid lixivium not only efficiently removes excess iron impurities leached due to the poor selectivity of hydrochloric acid, but also enables the high-value utilization of these iron impurities. It enhances economic benefits while simultaneously alleviating environmental pressure.