Preparation and characterization of nano-particle LiFePO4 and LiFePO4/C by spray-drying and post-annealing method

Pure, nano-sized LiFePO₄ and LiFePO₄/C cathode materials are synthesized by spray-drying and post-annealing method. The influence of the sintering temperature and carbon coating on the structure, particle size, morphology and electrochemical performance of LiFePO₄ cathode material is investigated. The optimum processing conditions are found to be thermal treatment for 10 h at 600 °C. Compared with LiFePO₄, LiFePO₄/C particles are smaller in size due to the inhibition of crystal growth to a great extent by the presence of carbon in the reaction mixture. And that the LiFePO₄/C composite coated with 3.81 wt.% carbon exhibits the best electrode properties with discharge capacities of 139.4, 137.2, 133.5 and 127.3 mAh g⁻¹ at C/5, 1C, 5C and 10C rates, respectively. In addition, it shows excellent cycle stability at different current densities. Even after 50 cycles at the high current density of 10C, a discharge capacity of 117.7 mAh g⁻¹ is obtained (92.4% of its initial value) with only a low capacity fading of 0.15% per cycle.     

One-step microwave synthesis and characterization of carbon-modified nanocrystalline LiFePO4

The precursors of LiFePO₄ were prepared by a sol-gel method using lithium acetate dihydrate, ferrous sulfate, phosphoric acid, citric acid and polyethylene glycol as raw materials, and then the carbon-modified nanocrystalline LiFePO₄ (LiFePO₄/C) cathode material was synthesized by a one-step microwave method with the domestic microwave oven. The effect of microwave time and carbon content on the performance of the resulting LiFePO₄/C material was investigated. Structural characterization by X-ray diffraction and scanning electron microscopy proved that the olivine phase LiFePO₄ was synthesized and the grain size of the samples was several hundred nanometers. Under the optimal conditions of microwave time and carbon content, the charge-discharge performance indicated that the nanosized LiFePO₄/C had a high electrochemical capacity at 0.2 C (152 mAh g⁻¹) and improved capacity retention; the exchange current density was 1.6977 mA cm⁻². Furthermore, the rate capability was improved effectively after LiFePO₄ was modified with carbon, with 59 mAh g⁻¹ being obtained at 20 C.     

Enhanced electrochemical performance of nano-sized LiFePO4/C synthesized by an ultrasonic-assisted co-precipitation method

A simple and effective method, the ultrasonic-assisted co-precipitation method, was employed to synthesize nano-sized LiFePO₄/C. A glucose solution was used as the carbon source to produce in situ carbon to improve the conductivity of LiFePO₄. Ultrasonic irradiation was adopted to control the size and homogenize the LiFePO₄/C particles. The sample was characterized by X-ray powder diffraction, field-emission scanning electron microscopy (FE-SEM), transmission electron microscopy (TEM) and high-resolution transmission electron microscopy (HRTEM). FE-SEM and TEM show that the as-prepared sample has a reduced particle size with a uniform size distribution, which is around 50 nm. A uniform amorphous carbon layer with a thickness of about 4-6 nm on the particle surface was observed, as shown in the HRTEM image. The electrochemical performance was demonstrated by the charge-discharge test and electrochemical impedance spectra measurements. The results indicate that the nano-sized LiFePO₄/C presents enhanced discharge capacities (159, 147 and 135 mAh g⁻¹ at 0.1, 0.5 and 2 C-rate, respectively) and stable cycling performance. This study offers a simple method to design and synthesis nano-sized cathode materials for lithium-ion batteries.     

Properties of Li-graphite and LiFePO4 electrodes in LiPF6–sulfolane electrolyte

Sulfolane (also referred to as tetramethylene sulfone, TMS) containing LiPF₆ and vinylene carbonate (VC) was tested as a non-flammable electrolyte for a graphite |LiFePO₄ lithium-ion battery. Charging/discharging capacity of the LiFePO₄ electrode was ca. 150 mAh g⁻¹ (VC content 5 wt%). The capacity of the graphite electrode after 10 cycles establishes at the level of ca. 350 mAh g⁻¹ (C/10 rate). In the case of the full graphite |1 M LiPF₆ + TMS + VC 10 wt% |LiFePO₄ cell, both charging and discharging capacity (referred to cathode mass) stabilized at a value of ca. 120 mAh g⁻¹. Exchange current density for Li⁺ reduction on metallic lithium, estimated from electrochemical impedance spectroscopy (EIS) experiments, was j_o(Li/Li⁺) = 8.15 × 10⁻⁴ A cm⁻². Moreover, EIS suggests formation of the solid electrolyte interface (SEI) on lithium, lithiated graphite and LiFePO₄ electrodes, protecting them from further corrosion in contact with the liquid electrolyte. Scanning electron microscopy (SEM) images of pristine electrodes and those taken after electrochemical cycling showed changes which may be interpreted as a result of SEI formation. No graphite exfoliation was observed. The main decomposition peak of the LiPF₆ + TMS + VC electrolyte (TG/DTA experiment) was present at ca. 275 °C. The LiFePO₄(solid) + 1 M LiPF₆ + TMS + 10 wt% VC system shows a flash point of ca. 150 °C. This was much higher in comparison to that characteristic of a classical LiFePO₄ (solid) + 1 M LiPF₆ + 50 wt% EC + 50 wt% DMC system (T_f ≈ 37 °C).     

Effect of CeO2-coating on the electrochemical performances of LiFePO4/C cathode material

The effect of CeO₂ coating on LiFePO₄/C cathode material has been investigated. The crystalline structure and morphology of the synthesized powders have been characterized by XRD, SEM, TEM and their electrochemical performances both at room temperature and low temperature are evaluated by CV, EIS and galvanostatic charge/discharge tests. It is found that, nano-CeO₂ particles distribute on the surface of LiFePO₄ without destroying the crystal structure of the bulk material. The CeO₂-coated LiFePO₄/C cathode material shows improved lithium insertion/extraction capacity and electrode kinetics, especially at high rates and low temperature. At −20 °C, the CeO₂-coated material delivers discharge capacity of 99.7 mAh/g at 0.1C rate and the capacity retention of 98.6% is obtained after 30 cycles at various charge/discharge rates. The results indicate that the surface treatment should be an effective way to improve the comprehensive properties of the cathode materials for lithium ion batteries.     

Process investigation, electrochemical characterization and optimization of LiFePO4/C composite from mechanical activation using sucrose as carbon source

LiFePO₄/C composite was synthesized by mechanical activation using sucrose as carbon source. High-energy ball milling facilitated phase formation during thermal treatment. TG-DSC and TPR experiments demonstrated sucrose was converted to CH_x intermediate before completely decomposed to carbon. Ball milling time, calcination temperature and dwelling time all had significant impact on the discharge capacity and rate performance of the resulted power. The optimal process parameters are high-energy ball milling for 2-4 h followed by thermal treatment at 700 °C for 20 h. The product showed a capacity of 174 mAh/g at 0.1C rate and around 117 mAh/g at 20C rate with the capacity fade less than 10% after 50 cycles. Too low calcination temperature or insufficient calcination time, however, could result in the residual of CH_x in the electrode and led to a decrease of electrode performance.     

Synthesis of LiFePO4/C by solid-liquid reaction milling method

LiFePO₄/C was synthesized by the method of solid-liquid reaction milling, using FeCl₃·6H₂O, Li₂CO₃ and (NH₄)₂HPO₄ and glucose, which was used as reductant (carbon source). The samples were characterized by X-ray diffraction (XRD), scanning electron microscope (SEM), TG-DTA analysis, infrared absorption carbon-sulfur analysis and electrochemical performance test. The sample synthesized at 680 °C for 8 h showed, at initial discharge, a capacity of 155.8, 153.2, 148.5, 132.7 mAh g^− 1 at 0.2 °C, 0.5 °C, 1 °C and 3 °C rate respectively. The sample also showed an excellent capacity retention as there was no significant capacity fade after 10 cycles.     

Electrochemical properties of carbon-mixed LiFePO4 cathode material synthesized by the ceramic granulation method

LiFePO₄/carbon composite cathode material was prepared using polyvinyl alcohol (PVA) as carbon source by pelleting and subsequent pyrolysis in N₂. The samples were characterized by XRD, SEM and TGA. Their electrochemical performance was investigated in terms of charge–discharge cycling behavior. It consists of a single LiFePO₄ phase and amorphous carbon. The special micro-morphology via the process is favorable for electrochemical properties. The discharge capacity of the LiFePO₄/C composite was 145 mAh/g, closer to the theoretical specific capacity of 170 mAh/g at 0.1 C low current density. At 3 C modest current density, the specific capacity was about 80 mAh/g, which can satisfy for transportation applications if having a more planar discharge flat.     

Synthesis of FePO4·xH2O for fabricating submicrometer structured LiFePO4/C by a co-precipitation method

Amorphous hydrated iron (III) phosphate has been synthesized by a coordinate precipitation method from equimolecular Fe(NO₃)₃ and (NH₄)₂HPO₄ solutions at an elevated temperature. Hydrated iron (III) phosphate samples and the corresponding LiFePO₄/C products were characterized by XRD and SEM. The electrochemical behavior was studied by cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS). The LiFePO₄/C fabricated from as-synthesized FePO₄ delivered discharge capacities of 162.5, 147.3, 133.0, 114.7, 97.2, 91.3 and 88.5 mAh g⁻¹ at rates of 0.1C, 0.2C, 0.5C, 1C, 2C, 3C and 4C with satisfactory capacity retention, respectively.     

Influence of carbon sources on LiFePO4/C composites synthesized by the high-temperature high-energy ball milling method

Carbon-coated LiFePO₄ composites were synthesized by a new method of high-temperature high-energy ball milling (HTHEBM). Fe₂O₃ and LiH₂PO₄ were used as raw materials. Glucose, sucrose, citric acid and active carbon were used as reducing agents and carbon sources, respectively. In this method, high-energy ball milling and carbon coating worked together and, therefore, fine and homogeneous LiFePO₄/C particles with excellent properties were obtained in a relatively short synthesis time of 9 h. Moreover, the synthesis process could be completely finished at a relatively lower temperature of 600 °C for high-energy ball milling transforming mechanical energy into thermal energy. The results of X-ray diffraction (XRD) analysis, scanning electron microscopy (SEM), transmission electron microscopy (TEM) and electrochemical performance tests indicated that carbon source had an important influence on the properties of LiFePO₄/C composites synthesized by the HTHEBM method. It was proved that the LiFePO₄ composites coated with glucose had the best properties with 1 μm geometric mean diameter and 150.3 mA h g⁻¹ initial discharge capacity at a current rate of 0.1 C. After the 20th cycle test, the reversible capacity was 148 mA h g⁻¹ at 0.1 C, showing a retention ratio to the initial capacity of 98.5%.     

Optimization of electrochemical properties of LiFePO4/C prepared by an aqueous solution method using sucrose

LiFePO₄ can be used as a positive electrode material for lithium-ion batteries by making composite with electrical conductive carbonaceous materials. In this study, LiFePO₄/C (carbon) composite was prepared by a soft chemistry route, in which sucrose was used as a carbon source of a low price. We tried to optimize a Li/(LiFePO₄/C) cell performance through changing synthetic conditions and discussed the factors affecting the electrochemical performances of the cell, such as the amount of the carbon source, synthetic temperature, gas flow rate of pyrolysis and the formation of secondary phases. It was found that the connection of the residual carbon and Fe₂P to LiFePO₄ particles and the amount of these two phases were important factors. In our experimental conditions, LiFePO₄/C including 9.72 wt.% of residual carbon, prepared at 800 °C for 12 h showed the highest reversible capacity and the best C rate performance among the synthesized materials; 130 mAh g⁻¹ at 10C rate and 50 °C.     

Preparation of synthetic rutile and metal-doped LiFePO4 from ilmenite

The synthetic rutile and metal-doped LiFePO₄ are prepared from the high-titanium residue and iron-rich lixivium, which are obtained from the ilmenite by a mechanical activation and leaching process. ICP results show that the rutile contains 92.01% TiO₂, 1.59% Fe₂O₃, 0.034% MnO₂ and 0.60% (MgO + CaO), which meet the requirement of the titanium dioxide chlorination process. The results also reveal that small amounts of Al³⁺, Ca²⁺ and Ti⁴⁺ precipitate in the FePO₄·xH₂O precursor. XRD and Rietveld-refine results show that the metal-doped LiFePO₄ is single olivine-type phase and well crystallized, and Ti⁴⁺ occupy M1 site, Ca²⁺ occupy M2 site and Al³⁺ occupy both sites, which indicates the formation of cation-deficient solid solution. The sample exhibits a capacity of 123 mAh g⁻¹ at 5C rate, and retains 94.3% of the capacity after 100 cycles.     

Effect of milling method and time on the properties and electrochemical performance of LiFePO4/C composites prepared by ball milling and thermal treatment

Effects of ball milling way and time on the phase formation, particulate morphology, carbon content, and consequent electrode performance of LiFePO₄/C composite, prepared by high-energy ball milling of Li₂CO₃, NH₄H₂PO₄, FeC₂O₄ raw materials with citric acid as organic carbon source followed by thermal treatment, were investigated. Three ball milling ways and five different milling durations varied from 0 to 8 h were compared. LiFePO₄/C composites could be obtained from all synthesis processes. TEM examinations demonstrated LiFePO₄/C from ball milling in acetone resulted in sphere shape grains with a size of ∼60 nm, similar size was observed for LiFePO₄/C from dry ball milling but in a more irregular shape. The ball milling in benzene resulted in a much larger size of ∼250 nm. The LiFePO₄/C composites prepared from dry ball milling and ball milling in acetone showed much better electrochemical performance than that from ball milling in benzene. SEM examinations and BET measurements demonstrated that the high-energy ball milling effectively reduced the grain size. A ball milling for 4 h resulted in the best electrochemical performance, likely due to the proper amount of carbon and proper carbon structure were created.     

Reaction mechanism and electrochemical performance of LiFePO4/C cathode materials synthesized by carbothermal method

Spray drying and carbothermal method was employed to investigate reaction mechanism and electrochemical performance of LiFePO₄/C cathode by using different carbon sources. Micro-structural variations of LiFePO₄/C precursors using different carbon sources were studied by Thermo-gravimetric (TG)/Differential Thermal Analysis (DTA). The LiFePO₄/C samples were characterized by X-ray diffraction (XRD) and Fourier transform infrared (FTIR) absorption spectroscopy. The results indicated that the crystallization temperature of LiFePO₄ was 453 °C, while the transform temperature was 539 °C from Li₃Fe₂(PO₄)₃ to LiFePO₄. At 840 °C, LiFePO₄/C sample with an excess of impurity phase Fe₂P gave much poorer electrochemical performance. The severe decomposition of LiFePO₄/C happened at 938 °C and generated impurity phases Li₄P₂O₇ and Fe₂P. The clear discharge platform of Fe₂P emerged at around 2.2 V.     

Effect of lithium extraction on the stabilities,electrochemical properties,and bonding characteristics of LiFePO4 cathode materials: A first-principles investigation

The impact of lithium extraction on the structural stabilities, electronic structures, bonding characteristics, and electrochemical performances of LiFePO₄ compound was investigated by first-principles technique. The results demonstrated that the partition scheme of electrons not only affects the calculated atomic charges but also the magnetic properties. In FePO₄ and LiFePO₄ compounds, all Fe ions take high spin arrangements and have large magnetic moments (MMs), while the MMs of other ions are very small. The magnetisms of Li_xFePO₄ compounds are mainly originated form Fe ions. It was found that the changes in d band electrons of the transition metals do play an important role in determining the voltage of a battery (versus Li/Li⁺). Furthermore, the variations in d band electrons also provide us a method to control the density of states (DOS) and carrier concentration at the Fermi energy. Our calculations confirmed that the substitution of Fe by Co and Ni ions leads to a voltage increase by about 0.70 V and 1.23 V respectively. According to the bond populations, it can be identified that strong covalent bonds are formed between O and P ions. The P–O bonds are much stronger than Fe–O ones. The partial DOSs further revealed that the covalent bonds in Li_xFePO₄ are derived from the orbital overlaps between O_2s,2p and P_3s,3p states, and the overlap between Fe_3d and O_2p states. Such covalent bonds are of particularly importance for the excellent thermodynamic stabilities of the two-ends structures of Li_xFePO₄.     

LiFePO4 cathode power with high energy density synthesized by water quenching treatment

A water quenching (WQ) method was developed to synthesize LiFePO₄ and C-LiFePO₄. Our results indicate that this synthesis method ensures improved electrochemical activity and small crystal grain size. The synthetic conditions were optimized using orthogonal experiments. The LiFePO₄ sample prepared at the optimized condition showed a maximum discharge capacity of 149.8 mAh g⁻¹ at a C/10 rate. C-LiFePO₄ with a low carbon content of 0.93% and a high discharge specific capacity of 163.8 mAh g⁻¹ has also been obtained using this method. Water quenching treatment shows outstanding improvement of the electrochemical performance of LiFePO₄.     

In situ construction of carbon nano-interconnects between the LiFePO4 grains using ultra low-cost asphalt

LiFePO₄/C composite cathode materials with carbon nano-interconnect structures were synthesized by one-step solid state reaction using low-cost asphalt as both carbon source and reducing agent. Based on the thermogravimetry, differential scanning calorimetry, transmission electron microscopy and high-resolution transmission electron microscopy, a growth model was proposed to illustrate the formation of the carbon nano-interconnect between the LiFePO₄ grains. The LiFePO₄/C composite shows enhanced discharge capacity (150 mAh g⁻¹) with excellent capacity retention compared with the bare LiFePO₄ (41 mAh g⁻¹) due to the electronically conductive nanoscale networking provided by the asphalt-based carbon. The results prove that the asphalt is a perfect carbon source and reduction agent for cost-effective production of high performance LiFePO₄/C composite.     

Synthesis of LiFePO4/carbon composite from nano-FePO4 by a novel stearic acid assisted rheological phase method

LiFePO₄/carbon composite was synthesized at 600 °C for 4 h in an Ar atmosphere by a stearic acid assisted rheological phase method using amorphous nano-FePO₄ as the iron source. XRD, SEM and TEM observations show that the LiFePO₄/carbon composite has good crystallinity, ultrafine and well-dispersed particles of 60–150 nm size and in situ carbon coated on the surface of LiFePO₄ crystallites. The synthesized LiFePO₄/carbon composite shows a high discharge capacity of 160 mAh g⁻¹ and 155 mAh g⁻¹ at rates of 0.5 C and 1 C, respectively. Even at a high current density of 30 C, the material still presents a discharge capacity of 93 mAh g⁻¹ and exhibits an excellent cycling performance.     

Synthesis and characterization of LiFePO4/(Ag + C) composite cathodes with nano-carbon webs

LiFePO₄/(Ag + C) composite cathodes with a new type of nano-sized carbon webs were synthesized by two methods of an aqueous co-precipitation and a sol-gel process, respectively. Simultaneous thermogravimetric-differential thermal analysis indicates that the crystallization temperature of LiFePO₄ is about 455-466 °C, which is close to the pyrolysis temperature of polypropylene, 460 °C. The silver and carbon co-modifying does not affect the olivine structure of LiFePO₄ but improves its kinetics in terms of discharge capacity and rate capability. Discharge capacities were improved from 153.4 mA h g^− 1 of LiFePO₄/C to 160.5 mA h g^− 1and 162.1 mA h g^− 1 for LiFePO₄/(Ag + C) cathodes synthesized by the co-precipitation and sol-gel methods, respectively. The possible reasons for the small difference in discharge capacity of two LiFePO₄/(Ag + C) cathodes were discussed. AC impedance measurements show that the Ag + C co-modification decreases the charge transfer resistance of LiFePO₄/(Ag + C) cathodes.     

Synthesis and characterization of high-density LiFePO4/C composites as cathode materials for lithium-ion batteries

To achieve a high-energy-density lithium electrode, high-density LiFePO₄/C composite cathode material for a lithium-ion battery was synthesized using self-produced high-density FePO₄ as a precursor, glucose as a C source, and Li₂CO₃ as a Li source, in a pipe furnace under an atmosphere of 5% H₂-95% N₂. The structure of the synthesized material was analyzed and characterized by X-ray diffraction (XRD) and scanning electron microscope (SEM). The electrochemical properties of the synthesized LiFePO₄/carbon composite were investigated by cyclic voltammetry (CV) and the charge/discharge process. The tap-density of the synthesized LiFePO₄/carbon composite powder with a carbon content of 7% reached 1.80 g m⁻³. The charge/discharge tests show that the cathode material has initial charge/discharge capacities of 190.5 and 167.0 mAh g⁻¹, respectively, with a volume capacity of 300.6 mAh cm⁻³, at a 0.1C rate. At a rate of 5C, the LiFePO₄/carbon composite shows a high discharge capacity of 98.3 mAh g⁻¹ and a volume capacity of 176.94 mAh cm⁻³.