Direct Lithium Extraction from α-Spodumene through Solid-State Reactions for Sustainable Li 2 CO 3 Production
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37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
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Asymmetric pathways for lithium extraction and recovery based on the two-phase equilibrium of layered oxides
Electrochemical intercalation offers a promising platform for Li + extraction. However, only limited types of electrode materials have been investigated. The challenge to broaden and tailor materials for electrochemical intercalation-based Li + extraction lies in the lack of understanding of material’s response upon co-intercalation of multiple ions, therefore, paired process design to enable reversible Li + extraction and recovery. Here, we showcase the design of asymmetric ion pathways for Li + extraction and recovery for host material with complex Li + and Na + interaction using layered cobalt oxide as a model material. The two-phase equilibrium of Na 0.48 CoO 2 and Li 0.94 CoO 2 governs Li + selectivity when a high depth of intercalation is achieved (low vacancy level). We show that the relative rate between ion exchange and intercalation is critical to determine the ion pathways. The relationship can be quantitatively compared using the average pseudo ion exchange rate (C pseudoIX ) and the intercalation rate (C inter ). The ion pathways at the three regimes with C pseudoIX > C inter , C pseudoIX ~ C inter , and C pseudoIX < C inter are constructed. By selecting the optimized ion pathway and particle size, we demonstrate 9.7×10 4 Li + selectivity with 99% purity Li + recovery from an initial 1:1000 Li: Na molar ratio solution using 115 mAh/g specific capacity.
electrochemistry↗
Direct extraction of lithium from ores by electrochemical leaching
With the rapid increase in lithium consumption for electric vehicle applications, its price soared during the past decade. To secure a reliable and cost-effective supply chain, it is critical to unlock alternative lithium extraction resources beyond conventional brine. In this study, we develop an electrochemical method to directly leach lithium from α-phase spodumene. We find the H 2 O 2 promoter can significantly reduce the leaching potential by facilitating the electron transfer and changing the reaction path. Upon leaching, β-phase spodumene shows a typical phase transformation to HAlSi 2 O 6 , while leached α-phase remains its original crystal phase with a lattice shrinkage. To demonstrate the scale-up potential of electrochemical leaching, we design a catalyst-modified high-throughput current collector for high loading of suspended spodumene, achieving a leaching current of 18 mA and a leaching efficiency of 92.2%. Electrochemical leaching will revolutionize traditional leaching and recycling processes by minimizing the environmental footprint and energy consumption.
25 ENERGY STORAGE↗
A New Triketone Ligand for Extraction of Lithium from Brines**
Recovery of lithium from brines by liquid-liquid solvent extraction (LLE) with diketones and synergistic co-ligands has been investigated for decades, but industrial application has been limited. In pursuit of a ligand with improved properties, a series of ketonamides with beta-carbonyl groups were designed, synthesized, and tested in extraction of lithium from sulfate and carbonate simulants of clay mineral tailing leachates. The best performing ligand, a novel tricarbonyl amide, was characterized for lithium extraction with and without four synergistic co-ligands. Further, the tricarbonyl amide combined with the synergistic co-ligand Cyanex-923 was absorbed on a resin support. The ligand-modified resin was tested for performance in extraction of dilute brine simulants and up to 60 % recovery of lithium was achieved.
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Technology for the Recovery of Lithium from Geothermal Brines
Lithium is the principal component of high-energy-density batteries and is a critical material necessary for the economy and security of the United States. Brines from geothermal power production have been identified as a potential domestic source of lithium; however, lithium-rich geothermal brines are characterized by complex chemistry, high salinity, and high temperatures, which pose unique challenges for economic lithium extraction. The purpose of this paper is to examine and analyze direct lithium extraction technology in the context of developing sustainable lithium production from geothermal brines. In this paper, we are focused on the challenges of applying direct lithium extraction technology to geothermal brines; however, applications to other brines (such as coproduced brines from oil wells) are considered. The most technologically advanced approach for direct lithium extraction from geothermal brines is adsorption of lithium using inorganic sorbents. Other separation processes include extraction using solvents, sorption on organic resin and polymer materials, chemical precipitation, and membrane-dependent processes. The Salton Sea geothermal field in California has been identified as the most significant lithium brine resource in the US and past and present efforts to extract lithium and other minerals from Salton Sea brines were evaluated. Extraction of lithium with inorganic molecular sieve ion-exchange sorbents appears to offer the most immediate pathway for the development of economic lithium extraction and recovery from Salton Sea brines. Other promising technologies are still in early development, but may one day offer a second generation of methods for direct, selective lithium extraction. Initial studies have demonstrated that lithium extraction and recovery from geothermal brines are technically feasible, but challenges still remain in developing an economically and environmentally sustainable process at scale.
58 GEOSCIENCES↗
Magnetic Nanoparticle Extraction of Lithium from Produced Waters - CRADA 483 (Final Report)
The demand for lithium in the energy production industry is expected to increase sharply, development of simple and cost-effective techniques for lithium production and recovery from various lithium sources is essential. In this project, core/shell magnetic nanoparticles were successfully designed to selectively extract lithium from aqueous lithium sources as an extension of Pacific Northwest National Laboratory’s magnetic nanofluid extraction technology. The core/shell magnetic nanoparticles are composed of manganese oxide-based lithium ion sieve shells, which allow selective lithium uptake from brines with multiple coexisting ions, over iron oxide cores, which can respond to external magnetic fields for effective recovery and reuse of adsorbents from a liquid. The synthesized lithium ion-sieves and core/shell magnetic nanoparticles were characterized using several techniques to reveal their crystallinity and morphology. The lithium uptake properties of the lithium ion-sieves and core/shell magnetic nanoparticles were evaluated in terms of lithium adsorption capacity, removal percentage, selectivity, and cycling performance in simulated and natural brines. Magnetic properties of the core/shell magnetic nanoparticles were tested by measuring magnetic saturation, and magnetic response of colloidal solutions containing the core/shell magnetic nanoparticles was tested with permanent magnets.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Extraction of lithium from battery recycling wastewater using synergistic D2EHPA and TBP
The recycling of spent lithium-ion batteries (LIBs) poses significant challenges, including the generation of large volumes of chemically complex wastewater. The composition of this wastewater is influenced by both the intrinsic chemistry of the batteries and the specific recycling processes employed. Notably, this wastewater contains economically valuable components, such as lithium, which can be recovered. Here, in this study, a solvent extraction (SX) process was investigated as a method to recover lithium from battery recycling wastewater, especially from anode-washing stage. Initially, various commercial extractants were evaluated, including di(2-ethylhexyl)phosphoric acid (D2EHPA), mono-2-ethylhexyl (2-ethylhexyl)phosphonate (PC88A), bis(2,4,4-trimethylpentyl)phosphinic acid (Cyanex 272), 2-hydroxy-5-nonylacetophenone oxime (LIX 84-I), tri-butyl phosphate (TBP), and their combinations. Among these, D2EHPA + TBP demonstrated a synergism to advance and maximize the lithium extraction. Subsequently, the effects of key parameters, including D2EHPA concentration, TBP concentration, contact time, initial pH, and aqueous-to-organic (A/O) phase ratio, were systematically investigated and optimized. A two-stage SX approach was employed to enhance lithium recovery. Under the optimized conditions of 30.0 vol% D2EHPA, 10.0 vol% TBP, 10 min of contact time, and a 1:1 A/O phase ratio, a lithium extraction efficiency of more than 88% in a two-stage solvent extraction was achieved. Lithium was subsequently stripped from the loaded organic solution using sulfuric acid (H 2 SO 4 ). Using 2.0 M H 2 SO 4 , lithium stripping was achieved after two counter-current stripping stages at an organic-to-aqueous (O/A) phase ratio of 6:1. This stripping process enriched the lithium concentration by a factor of four compared to the original lithium concentration in the anode-washing wastewater. The recyclability of the synergistic D2EHPA + TBP system was also evaluated over four extraction-stripping cycles. The results demonstrated that the system maintained high extraction and stripping efficiencies.
D2EHPA↗
Life Cycle Assessment and Techno-Economic Assessment of Lithium Recovery from Geothermal Brine
Lithium-ion batteries (LIB) play an essential role in the electrification of the transportation sector, and battery demand for lithium compounds will see a significant increase in the coming decades. This has raised concerns on the supply of lithium, and as a result, technologies are being developed to process unconventional lithium sources. One promising technology is to extract lithium from geothermal brine using lithium-aluminum-layered double hydroxide chloride (LDH) sorbent and forward osmosis. A combined life cycle assessment (LCA) and techno-economic assessment (TEA) is conducted to evaluate the environmental and economic performance of this technology. It is assumed that the lithium extraction unit is an add-on to a 50 MW geothermal power plant located in California. The analysis is based on lab-scale experimental data and stoichiometry while considering the economy of scale for an industrial system. LCA results suggest that, compared with conventional LiOH and Li 2 CO 3 production pathways, the new technology achieves 1–95% reduction in environmental impacts. Even higher reduction can be achieved for LiOH produced via electrolysis. This add-on unit for lithium extraction could achieve a payback period of less than 1 year and reach net present values of $454M and $315M and internal rates of return of 792 and 1130% for LiOH and Li 2 CO 3 production pathways, respectively. The favorable environmental and economic performance suggests that LDH sorption coupled with forward osmosis has great potential to enable the domestic production of battery lithium compounds and that further development should be carried out.
15 GEOTHERMAL ENERGY↗
Selective leaching and solvent extraction of Lithium from spent batteries
Pre-extracting Li from spent lithium-ion batteries (LIBs) is crucial because the recovery efficiency of Li is low after other critical metals have been extracted. Traditional methods involving black mass roasting followed by water leaching have resulted in the extraction of 76 % Li and 61 % Al. However, pre-leaching Li from pretreated black mass using an oxalic acid solution at both ambient and elevated temperatures significantly improved results, achieving 98.1 % Li, 99.5 % Al, and 100 % Fe extraction while leaving Ni, Co, Mn, and Cu behind under optimal conditions. Oxalic acid crystals were recovered by refrigerating the leach solution at temperatures below 5 °C and were reused with nearly identical leaching efficiency. Selective extraction of Li from the oxalate leach solution was achieved using Cyanex® 936P under optimal conditions. Here, due to its extremely low Li extraction efficiency, Dichloromethane proved unsuitable as a diluent. Comparative extraction tests using Cyanex® 936P, Cyanex® 272, and DEHPA in kerosene demonstrated that Cyanex® 936P is an excellent extractant for Li, effectively separating it from other impurities. Under optimal conditions, 98.8 % of available Li was extracted using 20 % Cyanex® 936P, compared to 51.1 % with Cyanex® 272 and 39.9 % with DEHPA in kerosene. Additionally, stripping Li from Cyanex® 936P using H 2 SO 4 and HCl was explored, with HCl yielding the best performance.
Black mass↗
Advanced Brine Processing to Enable U.S. Lithium Independence (CRADA Report)
Current production of LiOH, which is needed to make Li-ion battery cathode active materials, utilizes a multistep process including solar evaporation, precipitation with Na 2 CO 3 and then conversion to LiOH using Ca(OH) 2 . This process requires a large amount of land area for solar evaporation, the right weather conditions, and chemicals for the conversion process that result in NaCl and CaCO 3 waste products. The production of Ca(OH) 2 is very energy intensive and evolves significant quantities of CO 2 . An alternative process flow utilizing direct lithium extraction techniques, followed by a chemical free conversion process can have benefits in reducing the needed land requirements and chemicals for traditional brine processing. There are many potential direct lithium extraction technologies that are currently being developed. The direct lithium extraction process from typical brine sources will produce a LiCl solution with some impurities including typically high concentrations of Na. This brine then needs to be converted to LiOH for use in battery cathode production. Ideally this conversion could occur without the use of additional chemicals. Electrochemistry can do this conversion either via electrolysis or bipolar membrane electrodialysis (BPED) to produce LiOH and HCl in solution. BPED utilized bipolar membranes to split water, which has a reduced potential as compared to splitting water at electrodes into hydrogen and oxygen gas. This reduced potential required results in a significant energy savings for BPED over electrolysis methods. This CRADA project aimed to develop such an integrated process using direct lithium extraction followed by BPED to produce a LiOH solution. That solution can then be crystallized into battery grade LiOH. In particular, Albemarle utilized a direct lithium extraction process to produce a concentrated LiCl solution that could be used for the BPED process. The BPED process was first tested using various LiCl solutions with impurity ions added at bench scale to understand the effects of impurities and determine processing parameters. Then testing was performed using the direct lithium extracted brine at the bench scale before scaling the process up. After the process was scaled up a long duration test was carried out to estimate the lifetime of the membranes, which is key to the economics of the BPED process.
25 ENERGY STORAGE↗
A Novel Zwitterionic Chromatography Approach to Separate Lithium from Unconventional Resources
Lithium (Li) is a key element for clean energy technologies, and, accordingly, the global lithium demand has been increasing rapidly. Therefore, to meet the Li demand and maintain supply chain stability, it is critical to develop efficient lithium extraction technologies that allow exploitation of unconventional lithium resources, such as geothermal brines and inland brine streams. However, the recovery of Li from these resources is challenging due to low Li concentration, low ratios of Li/Na, Li/Mg, or Li/Ca, and complex feed compositions. To address this, we introduced a new Direct Lithium Extraction (DLE) process using Zwitterionic Chromatography (ZIC) to separate Li from other salts. Since salts are partitioned on ZIC under water elution, no reagent chemicals are needed, and the Li separation is not limited by the adsorption capacity. We prepared 13 different zwitterionic (ZI) resins to investigate the salt retention on various ZI groups and then screened out promising sorbents for efficient Li separation. It was found that salt retention was synergistically affected by the pore size and ZI configurations. Using carboxybetaine (QAC3CA) sorbents, multicomponent separations showed that Li can be partitioned from divalent salts or Na with selectivities of 1.8 or 1.9, respectively. Although the selectivity is relatively low, in real brine tests, Li was separated from Ca and Mg with 79.2 % yield, showing the potential for a continuous process to achieve high productivity and high yield. Simulation studies suggest the salt elution mechanism is related to the hydration reaction energy and the effective hydrated radius of cations.
critical minerals↗
Membranes for Lithium Recovery From Conventional and Unconventional Sources
Lithium has been deemed a critical mineral of national importance that finds uses in a wide range of applications, and its demand has been rising significantly in recent years. The urgency of meeting this demand requires lithium extraction from various aqueous sources such as continental brines, geothermal brines, seawater, produced water, and battery waste. While direct lithium extraction (DLE) technologies such as adsorption, ion exchange, and solvent extraction have emerged as possible solutions, membrane technologies are also being investigated for various sources and at different stages of the recovery process. Here, we analyze the application of membranes for pretreatment of lithium source waters, bring management, lithium/magnesium separation, lithium/sodium separation, and lithium hydroxide conversion, and evaluate performance metrics for critical lithium separations from the literature. We explore the potential of membranes at every stage of the recovery process and describe their current status and future prospects. We describe hypothetical process trains with integrated membrane technologies for each source type and address their feasibility and challenges. The potential energy and water impacts of membrane-integrated and conventional DLE processes are also critically considered alongside performance and selectivity metrics, and this is illustrated using examples and calculated from published technical reports. This paper thus provides a comprehensive overview of the application of membranes along every stage of the lithium recovery process, emphasizing the versatility and potential of membrane technologies for critical mineral recovery.
36 MATERIALS SCIENCE↗
Novel Zwitterionic Chromatography to Separate Lithium from Unconventional Resources
Since lithium (Li) is a key element for clean energy technologies, the global lithium demand is anticipated to increase rapidly. As a result, efficient lithium extraction technologies that allow the exploitation of unconventional lithium resources, such as geothermal brines and inland brine streams, are essentially needed to meet the Li demand and keep supply chains stable. However, because of low Li concentration, low ratio of Li/Mg or Li/Ca, and complex feed compositions in these feedstocks, using conventional hydrometallurgy or current Direct Lithium Extraction (DLE) processes are often chemical-intensive, requiring substantial amounts of reagent chemicals to recover Li at scale, resulting in large chemical footprints. Therefore, we developed a novel Zwitterionic Chromatography (ZIC) process to separate Li from these resources. Because Li can be partitioned from divalent salts on ZIC under water elution without using chemicals, exploiting the unconventional resources via a ZIC approach can be environmentally benign and sustainable. In this work, we will present the development of the ZIC process for DLE applications. Simulation studies for the Li separation mechanism in ZIC and the demonstration of a continuous ZIC process to separate Li from domestic inland brine and mining wastewater will be presented. Finally, the chemical and energy footprints of ZIC in comparison to other DLE processes will be discussed.
09 BIOMASS FUELS↗
Ultra-high efficient lithium recovery via terephthalic acid from spent lithium-ion batteries
The recovery of lithium from spent lithium-ion batteries (LIBs) is a critical step in advancing sustainability within the battery industry. Traditional lithium extraction methods from end-of-life LIBs predominantly rely on chemical leaching techniques. However, these methods often involve the excessive use of acids, leading to substantial environmental concerns. Additionally, their non-selective nature can compromise the purity of the recovered lithium salt. To achieve battery-grade purity, further purification and recovery processes are necessary. In this study, we introduce a universal and eco-friendly process for lithium recovery, employing terephthalic acid to selectively extract lithium prior to the recycling of other valuable metals. This innovative method achieves lithium recovery rates exceeding 98.53% from layered oxide cathodes and 98.53% from lithium iron phosphate cathodes, delivering an exceptional purity level of 99.95%. By demonstrating applicability across a variety of cathode materials, this approach establishes a universal, sustainable and efficient solution for LIB recycling. The high-purity lithium extraction enabled by this process supports the comprehensive utilization of valuable resources, contributing significantly to the development of a circular economy for battery materials.
Hou, Jiahui [Worcester Polytechnic Institute, MA (↗
Pillared Laminar Vermiculite Membranes with Tunable Monovalent and Multivalent Ion Selectivity
Effective membrane separation of Li + from Na + and Mg 2+ is crucial for lithium extraction from water yet challenging for conventional polymeric membranes. Two dimensional (2D) membranes with ordered laminar structures and tunable physicochemical properties offer distinctive ion-sieving capabilities promising for lithium extraction. Recently, phyllosilicates are introduced as abundant and cost-effective source materials for such membranes. However, their water instability and low inherent ion transport selectivity hinder practical applications. Herein, a new class of laminar membranes with excellent stability and tunable ion sieving is reported by incorporating inorganic alumina pillars into vermiculite interlayers. Crosslinking vermiculite flakes with alumina pillars significantly strengthens interlamellar interactions, resulting in robust water stability. Doping of Na + before the pillaring process reverses the membrane's surface charge, substantially boosting Li + separation from multivalent cations via electrostatic interactions. Lithium extraction is often complicated by the presence of co-existing monovalent cations (e.g., Na + ) at higher concentrations. Here, by introducing excess Na + into the membrane after the pillaring process, the separation of Li + from monovalent cations is enhanced through steric effects. This work realizes both monovalent/multivalent and monovalent/monovalent selective ion sieving with the same membrane platform. A separation mechanism is proposed based on Donnan exclusion and size exclusion, providing new insights for membrane design for resource recovery applications.
2D materials↗
Magnetic Nanoparticle Extraction of Lithium from Produced Waters: CRADA 483 [Abstract only]
In this project, we will synthesize, evaluate, and screen a set of new sorbents that have high capacity and selectivity for lithium. Sorbent performance will be evaluated by conducting Li extraction tests with produced water samples supplied by ConocoPhillips Company, Moselle Technologies, and Cascade Natural Resources. The best performing of these sorbents based on Li uptake capacity and selectivity will be produced as a magnetic nanoparticle and subjected to extended cycle testing in our laboratory bench-scale magnetic separator system. Moselle has acquired an exclusive license to the background IP associated with this magnetic nanoparticle mineral extraction technology and wishes to foster implementation of the technology in the oil & gas industry through this CRADA. Moselle will support PNNL in the design of a commercial-scale magnetic separator system tailored for lithium production. The goal is to collect sufficient information to support a decision by our industry partners to invest in a subsequent field demonstration at one of our partner’s field sites as a prerequisite to advancing this technology towards commercialization.
36 MATERIALS SCIENCE↗
Chemical-Free Lithium Separation from High-Salinity Brines Using Model-Informed and Machine Learning-Optimized Multi-Column Zwitterionic Chromatography
Direct Lithium Extraction (DLE) technologies often struggle to produce high-purity lithium salts from high-salinity brines, as current approaches require chemical-based elution, regeneration, and precipitation steps, resulting in significant environmental footprints. A novel salt fractionation approach using carboxybetaine resin, known as zwitterionic chromatography (ZIC), has demonstrated that lithium ions can be separated from divalent cations under high-salinity conditions using only water as eluent, with no regeneration required. To enable continuous and scalable deployment of this approach, we developed a chemical-free Multi-column Zwitterionic Chromatography (MZC) process and its theoretical and process models. To predict and optimize this nontraditional separation system, we introduced a novel anti-Langmuir isotherm, and the isotherm parameters were estimated through a machine learning-driven optimization based on artificial neural network ensembles with numerical feasibility assessment. Using machine learning-driven optimization, the MZC process achieved 98.0% lithium recovery, 99.5 % Li/(Li + Mg + Ca) purity, a 31.3% productivity increase, and a 33% reduction in water use compared to batch operation. The proposed MZC process enables lithium separation at $0.6-1.2 kg-1 Li, with costs dominated by resin manufacturing, while offering lower separation costs and carbon footprint compared with conventional carbonation. Overall, these findings position the MZC process as an effective polishing step within scalable and sustainable lithium production pipelines.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
The brine of the times
New processes directly extract lithium from dilute sources. The accelerating global push to reduce carbon emissions is driving substantial demand for clean energy technologies and the materials on which they depend. Nations are vying for critical minerals, such as lithium, cobalt, and rare earth elements), to produce electric vehicles, energy storage devices, and other low-carbon technologies. Tremendous attention focuses on lithium, which is primarily sourced from either hard rock called spodumene or natural brines—solutions containing lithium and other salts found in continental deposits, for example. However, mining lithium often involves energy-intensive, laborious processes. On pages 1438 and 1444 of this issue, Li et al. and Song et al., respectively, report efficient ways to extract lithium from dilute brine. In conclusion, these advances open up opportunities for sustainable extraction from unexploited dilute brines.
Darling, Seth B.↗