Sustainable LiFePo₄ and LiMn_xFe_1-xPo₄ (x=0.1 to 1) Cathode Materials for Lithium-Ion Batteries: A Systematic Approach from Mine to Chassis

We conducted a comprehensive literature review for LiFePO₄ (LFP) and LiMn_xFe_1-xPO₄ (x=0.1 to 1) (LMFP)-based lithium-ion batteries (LIBs), focusing primarily on electric vehicles (EVs), which account for approximately 90% of LIB consumption. Although numerous individual research studies exist, a unified and coordinated review that covers the subject from mine to chassis is notably absent. Accordingly, our review encompasses the entire LIB development process, starting with <i>I)</i> initial resources, including lithium (Li), iron (Fe), manganese (Mn), and phosphorous (P), their global reserves, mining procedures, and their demand in LIB production. Then, we examined <i>II)</i> the main Fe- and Mn-containing precursors of Fe⁰, Fe_xO_y, FePO₄, FeSO₄, and MnSO₄, focusing on their preparation methods, employment in LIBs, and their effect on the electrochemical performance (EP) of the final active cathode materials (ACMs). These two steps are followed by <i>III)</i> utilizing these precursors in synthesizing ACMs. Specific attention is paid to the pioneering synthesis methods in olivine production lines, particularly hydrothermal liquid-state synthesis (LSS), molten-state synthesis (MSS), and solid-state synthesis (SSS). Afterward, we described <i>IV)</i> electrode engineering and design and optimization of electrolytes and <i>V) </i>the production of cells, modules, and packs. Finally, <i>(VI)</i> our review underscored the challenges associated with the widespread utilization of olivines in LIBs, emphasizing safety, cost, energy efficiency, and carbon emission. In conclusion, our review offers a comprehensive overview of the entire trajectory involved in the fabrication of LFP/LMFP-based LIBs, spanning from the initial elements in the mine to the assembly of final packs that power EVs.