Volume 117
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Theoretical criteria for particle size distribution of high compacted density LiFePO4 based on packing density modeling
Jinshun Lei a, Huanfeng Huang b, Lv Zhang a, Dewen Zeng a *, Zhongwei Zhao c
a College of Chemistry and Chemical Engineering, Central South University, Changsha, 410083, China
b Guangdong Guanghua Sci-Tech Co. Ltd, Shantou, 515061, China
c School of Metallurgy and Environment, Central South University, Changsha, 410083, China
10.1016/j.partic.2026.08.017
Volume 117, October 2026, Pages 524-533
Received 1 July 2026, Revised 13 August 2026, Accepted 15 August 2026, Available online 17 August 2026, Version of Record 26 August 2026.
E-mail: dewen_zeng@hotmail.com

Highlights

• Packing model links PSD to LFP compacted density.

• Model predictions agree with experimental trends.

• Theoretical compacted-density limits are defined by PSD span.

• D90/D10 > 5 is required for compacted density above 2.6 g cm−3.


Abstract

Compacted density can be effectively improved by optimizing the particle size distribution (PSD) of LiFePO4 (LFP) materials. However, high-density LFP materials are still mainly developed through experimental trial-and-error approaches, and the quantitative relationship between PSD characteristics and compacted density remains unclear. As a result, the minimum theoretical PSD requirements for achieving a target compacted density remain unclear. In this work, seven LFP samples with different PSD characteristics were prepared. A packing density model was employed to predict their compacted densities. The predictions agree well with experimental measurements, demonstrating the reliability and applicability of the model for LFP systems. Based on the model, theoretical criteria for high-density LFP materials are systematically identified. The results indicate that: (1) the maximum achievable compacted density is primarily controlled by the particle size span D90/D10, with larger values leading to higher upper limits; (2) for an LFP system with fixed D90 and D10, the maximum compacted density is uniquely determined and cannot be exceeded by varying the distribution in the intermediate size range (D20–D80); and (3) D90/D10 > 5 represents the minimum theoretical requirement for achieving a compacted density above 2.6 g cm−3 in LFP materials.

Graphical abstract
Keywords
LiFePO4 materials; Compacted density; Particle size distribution; Packing density model