With　the　rapid　development　of　lithium-ion　batteries,　the　recycling　of　spent　batteries　represents　a　major　future　challenge,　particularly　LiFePO4　batteries　(LFP)　due　to　their　structural　stability　and　high　safety.　This　study　proposes　a　simple　and　efficient　pretreatment　process,　employing　a　combination　of　ultrasonic-assisted　dilute　alkali　leaching　and　crushing-gas　sorting　to　separate　the　cathode　and　anode　material　from　spent　LFP,　respectively.　The　key　parameters　that　affect　the　recovery　efficiency　of　cathode　materials　from　Al　foil　have　been　determined,　including　alkali　concentration,　liquid-solid　ratio,　ultrasonic　frequency,　and　ultrasonic　time.　The　separation　efficiency　between　Al　foil　and　cathode　material　can　achieved　99.85　%.　The　interface　effect　generated　by　the　ultrasound　cavitation　promotes　the　separations　of　Al　foil　and　cathode　active　materials.　Meanwhile,　the　optimal　crushing-gas　sorting　process　parameters　including　particle　size　and　gas　flow　rate　was　determined　to　recover　Cu　foil　and　graphite　from　the　anode　active　material.　A　Cu　recovery　efficiency　of　87.2　%　with　a　Cu　grade　of　84.6　%　was　reached.　Additionally,　treatment　with　3　%　HCl　for　90　min　was　introduced　to　remove　the　residual　Li　in　the　recovered　graphite.　This　method　can　provide　a　more　efficient　and　sustainable　way　for　the　comprehensive　separation　and　recovery　of　active　materials　from　spent　lithium-ion　batteries.　©　2025　Elsevier　B.V.