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In the production of lithium iron phosphate (LFP) cathode active materials, filtration plays a critical role in ensuring product quality, process efficiency, and environmental compliance. The ammonium-based synthesis method for ferric phosphate generates process streams that contain valuable solids and impurities. Without effective filtration, these streams can lead to material loss, equipment fouling, and increased operational costs.
The customer aimed to maximize the recovery of ferric phosphate and ammonium phosphate while ensuring that the treated effluent met stringent environmental standards for industrial wastewater. Advanced filtration solutions were essential to recover valuable materials, protect downstream systems, and support sustainable manufacturing practices.
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Challenge
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Solution
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Results
A leading LFP cathode material manufacturer in China faced critical filtration challenges during the ammonium-based ferric phosphate production process:
- Low Filtration Precision: Existing plate frame filters (≥5 µm) failed to capture fine ferric phosphate particles.
- Material Loss: 0.3%–1% of ferric phosphate was lost in the mother liquor and wash water.
- High Maintenance & Labor: Frequent clogging and filter cloth replacements increased manual labor and reduced consistency.
- Downstream Damage: Residual particles caused blockages and damage to ultrafiltration membranes, compromising environmental compliance and increasing maintenance costs.
To address these issues, Pall conducted lab validation and recommended the Pall Dia-Filtroplast, a high-efficiency, backwashable candle filter system with a nominal filtration rating of <1 µm. Installed downstream of the plate frame filter, the system delivered:
- Enhanced Particle Retention: Captured fine ferric phosphate particles from process streams.
- Improved Material Recovery: Increased yield of ferric phosphate and recovery of ammonium phosphate.
- Protection of Downstream Equipment: Prevented fouling and damage to ultrafiltration membranes.
- Reduced Manual Intervention: Automated backwash capability minimized labor and maintenance frequency.
By implementing Pall Dia-Filtroplast, the customer achieved:
- Finer particle capture
- Improved material recovery
- Stable operation of water treatment systems
- Reduced manual maintenance
Compliance with GB 8978-1996 Integrated Wastewater Discharge Standard, including:
- Suspended Solids (SS): ≤ 70 mg/L
- COD: ≤ 100 mg/L
- NH₃-N: ≤ 15 mg/L
- Total Phosphorus (TP): ≤ 0.5 mg/L
- Heavy Metals: 0.1–1.5 mg/L
- pH: 6–9
Conclusion
This case highlights the transformative impact of precision filtration in LFP cathode material production. With Pall Dia-Filtroplast, the manufacturer not only improved operational efficiency and product recovery but also ensured environmental compliance—supporting sustainable, high-performance battery material manufacturing.
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