Lithium Iron Phosphate - Improvement of LFP Synthesis Processes

Improvement of LFP Synthesis Processes

Similar to lithium oxides, LiMPO₄ may be synthesized by the following methods: 1. solid-phase synthesis, 2. emulsion drying, 3. sol-gel process 4. solution coprecipitation, 5. vapor phase deposition, 6. electrochemical synthesis, 7. electron beam irradiation, 8. microwave process 9. hydrothermal synthesis, 10. ultrasonic pyrolysis, 11. spray pyrolysis, etc. Different processes have different results. For example, in the emulsion drying process, the emulsifier is first mixed with kerosene. Next, the solutions of lithium salts and iron salts are added to this mixture. This process produces carbon particles of nano sizes. Hydrothermal synthesis produces LiMPO₄ with good crystallinity. Conductive carbon is obtained by adding polyethylene glycol to the solution followed by thermal processing. Vapor phase deposition produces a thin film LiMPO₄.

LFP batteries also have their drawbacks. There are ongoing international patent suits regarding this technology, and mass production with stable and high quality still faces many challenges. The current low production levels mean that LFP batteries tend to cost more than their LiCoO₂ equivalents. The energy density of LFP batteries is significantly lower than LiCoO₂ (although well higher than its main competitor for safety and lifespan, the nickel-metal hydride battery), and the market acceptance for large batteries is rather low in certain applications, making LFP batteries harder to commercialize.