ETD

• LFP
• modeling
• recycling

This thesis presents the development of a simulation model for the continuous hydrometallurgical recycling of LiFePO₄ (LFP) batteries. The model, implemented in Python, provides a granular representation of each unit operation, from leaching to final lithium carbonate recovery, integrating experimental data supplied by Polo Tecnologico Magona (CPTM) with thermodynamic correlations from literature. Despite limited kinetic and thermodynamic data available in the literature, the model successfully reconstructs the behaviour of the process at steady state and identifies the key parameters governing system performance.

The analysis reveals that lithium recovery is strongly influenced by the efficiencies of the first two separation steps and by the lithium concentration targeted in the concentrator. Higher outlet concentrations decrease utility demand and enhance overall recovery, while the introduction of a recycle loop increases Li₂CO₃ yield from 35% to 78%. Alternative configurations of the concentration step, particularly the triple-effect evaporator and the evaporative crystallizer, significantly reduce energy consumption.

A preliminary gate-to-gate Life Cycle Assessment (LCA) confirms the environmental relevance of the hydrometallurgical route, showing that recovering lithium and metallic residues substantially reduces the impact associated with primary raw-material extraction. Although discrepancies with CPTM batch experiments arise—mainly due to modelling a continuous steady-state process—the results provide a coherent foundation for future development. Overall, this work demonstrates the potential of process modelling as a strategic tool for designing efficient and sustainable LFP recycling technologies and outlines the experimental and computational steps needed to advance towards industrial implementation.