GB2608460A - Process for the recovery and reuse of sulphate reagents from brines derived from lithium micas - Google Patents

Process for the recovery and reuse of sulphate reagents from brines derived from lithium micas Download PDF

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Publication number
GB2608460A
GB2608460A GB2109645.8A GB202109645A GB2608460A GB 2608460 A GB2608460 A GB 2608460A GB 202109645 A GB202109645 A GB 202109645A GB 2608460 A GB2608460 A GB 2608460A
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United Kingdom
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lithium
mica
brine
glauber salt
salt
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GB2109645.8A
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GB202109645D0 (en
Inventor
Smith Roderick
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British Lithium Ltd
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British Lithium Ltd
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Priority to GB2109645.8A priority Critical patent/GB2608460A/en
Publication of GB202109645D0 publication Critical patent/GB202109645D0/en
Priority to PCT/EP2022/068229 priority patent/WO2023275345A2/en
Publication of GB2608460A publication Critical patent/GB2608460A/en
Pending legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00Preliminary treatment of ores or scrap
    • C22B1/02Roasting processes
    • C22B1/06Sulfating roasting
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01DCOMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
    • C01D15/00Lithium compounds
    • C01D15/06Sulfates; Sulfites
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00Silicon; Compounds thereof
    • C01B33/20Silicates
    • C01B33/36Silicates having base-exchange properties but not having molecular sieve properties
    • C01B33/38Layered base-exchange silicates, e.g. clays, micas or alkali metal silicates of kenyaite or magadiite type
    • C01B33/42Micas ; Interstratified clay-mica products
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01DCOMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
    • C01D5/00Sulfates or sulfites of sodium, potassium or alkali metals in general
    • C01D5/16Purification
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00Preliminary treatment of ores or scrap
    • C22B1/02Roasting processes
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B26/00Obtaining alkali, alkaline earth metals or magnesium
    • C22B26/10Obtaining alkali metals
    • C22B26/12Obtaining lithium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/04Extraction of metal compounds from ores or concentrates by wet processes by leaching
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00Preliminary treatment of ores or scrap
    • C22B1/14Agglomerating; Briquetting; Binding; Granulating
    • C22B1/24Binding; Briquetting ; Granulating
    • C22B1/2406Binding; Briquetting ; Granulating pelletizing
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/20Recycling

Abstract

A process comprising calcining a magnetic lithium mica feed in the presence of a sulphate salt and at least one of lime or calcium carbonate. The calcined material is subjected to aqueous leaching with a solid percentage in the slurry of 5-40%, at atmospheric pressure and a temperature of 5-95 °C to make a leached, calcined lithium mica material and brine. The brine is cooled, preferably to less than 10 °C, to precipitate Glauber salt (e.g. sodium sulfate decahydrate, Na2SO4.10H2O), followed by recovery of the Glauber salt. The recovered Glauber salt may be reintroduced into the calcining step. The precipitation step may comprise addition of a seeding material, such as one or more of calcium, sodium, potassium or magnesium sulphates. Lithium mica material may include zinnwaldite, lepidolite, siderophyllite or polylithionite.

Description

PROCESS FOR THE RECOVERY AND REUSE OF SULPHATE REAGENTS FROM BRINES DERIVED FROM LITHIUM MICAS
The present invention relates to a process for recovery of Glauber Salt from a brine or leach solution derived from aqueous leaching of lithium-mica minerals after roasting in the presence of sulphate salts to produce a water-soluble lithium. The process of the present invention can be used to achieve >95% recovery of Glauber Salt for reuse as a roasting reagent.
BACKGROUND OF INVENTION
Lithium micas present an important source of lithium that is likely to grow in significance as the demand for lithium is expected to increase considerably in light of a worldwide effort to reduce carbon emissions.
Lithium is predominantly used to make battery chemicals. It is extracted from brines and hard rock deposits containing spodumene. The former involves pumping and evaporation of vast quantities of water to extract and concentrate brines before impurity removal to produce a final lithium salt product. Spodumene, a lithium-bearing pyroxene mineral, is mined from hard rock deposits and typically requires roasting and acid leaching to produce a lithium-enriched brine or pregnant leach solution that is then purified to obtain a final lithium salt product.
Alongside spodumene, lithium in mica can also present potentially economic deposits. These occur within granites in Europe and elsewhere, which also contain gangue minerals, principally quartz and feldspar. However, lithium is currently not extracted commercially from lithium-mica and so to exploit these deposits commercially there is a need to develop an environmentally sustainable and economic methods for extraction of lithium salts of acceptable quality from these micas.
Lithium-mica minerals such as zinnwaldite (KLiFeAl(A15i3)010(OH,F)2; potassium lithium iron aluminium silicate hydroxide fluoride) and lepidolite (KLi2AlSi4010(OH,F)2) are tri-octahedral mica minerals that exist in a solid solution series whose end members are siderophyllite (KFe2Al(A12512010)(F,OH)2; potassium iron aluminium silicate hydroxide fluoride) and polylithionite (KLi2Al(Si4010)(F,OH)2;potassium lithium aluminium silicate hydroxide fluoride).
They contain a wider range of elements than spodumene LiAl(Si206) (lithium aluminium inosilicate) and, consequently, they are less rich in lithium. For instance, the lithium content of pure zinnwaldite is 1.59% by mass, compared to 3.73% for spodumene.
Given the disadvantages of lithium-mica minerals of lower grade and higher mineral complexity compared to spodumene there is a need for a refining process for brines derived from lithium-mica minerals with improved lithium recovery efficiency, with fewer processing steps, improved specificity for a particular ore, at lower cost and lower environmental impact. There is also a need for a beneficiation process which does not require the use of environmentally damaging reagents or processes.
Calcining of lithium mica in the presence of sulphate ions such as those contained in sodium or calcium sulphate provides a means of rendering the lithium contained in the minerals water soluble through a solid-state reaction. An aqueous leaching step after the calcining brings the lithium and other mobilised species, including the sulphates, alkalis and earth alkalis into solution in the form of aqueous cations. Subsequently, these impurities need removing from the brine or pregnant leach solution as part of impurity removal steps to facilitate purification of lithium to a saleable quality of lithium salt. At this stage, disposal of the sulphate ions would be a wasteful and environmentally unsustainable practice as well as being detrimental to the economics of the lithium refining process. The present invention relates to a method of recovery and recycling of reagents to abate the environmental impact and improve the economics of the purification of lithium brines.
The major sources of commercially mined lithium are from brine solutions (principally in South America) and spodumene containing ores (principally in Western Australia). Currently, there is no commercial production of lithium from lithium-mica rich ores or concentrates.
Leaching of mica using sulphuric acid at elevated temperatures, either at atmospheric pressure or in an autoclave or other device to increase pressure, is well described but does not rely on sodium sulphate. This process, whilst avoiding the need for calcining, utilises vast quantities of sulphuric acid that will need appropriate arrangements for environmentally friendly disposal.
Sulphate salts, including lithium sulphate, are readily soluble and therefore provide a clear route towards producing a lithium-enriched brine. This requires calcining of lithium mica at a temperature above 800° C in the presence of a salt of sulphate such as sodium sulphate or anhydrous gypsum. This produces a lithium-enriched brine that also contains a large quantity of sodium of calcium sulphate in solution.
Recovery of sodium sulphate in the form of Glauber salt (sodium sulphate decahydrate) is an important step to make the overall sulphate roasting -aqueous leaching process as environmentally friendly and economic as possible. From a review of other known methods, recoveries of Glauber salt in the region of that achieved in the presented invention is not documented in literature.
SUMMARY OF INVENTION
According to a first aspect of the invention, there is provided a Glauber salt (sodium sulphate decahydrate) crystallised and recycled from a brine derived from the leaching of calcined lithium mica-material containing feed by cooling of said brine.
According to a second aspect, there is provided a process for providing a Glauber salt from a brine derived from the leaching of calcined lithium mica-material containing feed, the process comprising: exposing a magnetic lithium mica-material containing feed with a Li grade in excess of 1% Li to heat (i.e. calcining) in the presence of sodium sulphate and at least one of: lime and/or calcium carbonate to provide a calcined lithium mica-material containing feed; aqueous leaching of the calcined lithium mica-material containing feed at a solids percentage in the slurry between 5% and 40%, operating at atmospheric pressure and at temperatures between 5°C and 95°C to generate a leached, calcined lithium mica-material and brine; cooling the brine to a predetermined temperature to cause Glauber salt to precipitate to generate lithium-enriched brine; and recovery of the Glauber salt by filtration at a temperature below 33°C The heat is preferably sufficient to cause a solid state reaction.
According to a third aspect of the present invention, there is provided a process for calcining magnetic lithium mica material comprising: obtaining a Glauber salt from a brine derived from the leaching of calcined lithium mica-material containing feed using a process as herein described; and reintroducing the recovered Glauber salt into the step of exposing the magnetic lithium mica material to heat (i.e. calcining).
The calcining step preferably comprises heating magnetic lithium mica material in the presence of sodium sulphate, for example to a temperature between 750 and 850 °C at a residence time in the hot zone of less than 50 minutes and under an oxidising atmosphere.
The Glauber salt is preferably sodium sulphate decahyd rate.
The cooling step may comprise cooling the brine to a temperature of less than 33°C, for example to a temperature of less than 10 °C, to achieve a high yield of Glauber salt for recycling as a reagent.
The precipitation step may further comprise the addition of a seeding material to provide nucleation points to achieve a high yield of Glauber salt for recycling as a reagent. The seeding material may comprise one or more of: calcium sulphate seed crystals and/or sodium sulphate seed crystals and/or potassium sulphate seed crystals and/or magnesium sulphate seed crystals.
The process may further comprise the addition of one or more hydroxide salt(s) and/or carbonate salt(s) to the brine. The one or more hydroxide salt(s) and/or carbonate salt(s) may be included in the process ahead of crystallisation to facilitate removal of impurities from for example the brine. The impurities may include, but not limited to, one or more of: iron, titanium, magnesium and potassium.
Preferably, the lithium mica-material containing feed is a milled, preferably a milled and beneficiated, feed stream.
The lithium mica-material containing feed may be provided or formed from igneous rock.
The igneous rock may have been formed during the Variscan Orogeny. The igneous rock may form for example be a felsic intrusive rock such as a granite intrusion part of the Cornubian batholith, the Bohemian Batholiths, the Moldanubian Plutonic Complex or the Central French Massif.
The lithium mica-material containing feed is preferably derived from naturally deposited lithium-mica-bearing sediments or anthropogenically generated waste streams or lithium-mica bearing storage dams derived from naturally deposited lithium-mica-bearing rock or sediments.
Embodiments of the present invention will now be described in further detail in relation to the accompanying Figures:
BRIEF DESCRIPTION OF FIGURES
Figure 1 is a schematic illustration of the Glauber salt crystallisation process according to one embodiment of the present invention; and Figure 2 shows an example embodiment of a precipitation apparatus used for precipitation of Glauber salt from a brine derived from magnetic lithium mica-material containing feed.
DETAILED DESCRIPTION
According to one embodiment, the lithium-enriched brine that forms the feed to the Glauber salt crystallisation stage of the process may contain between 0.1 and 45g/I of lithium (Li). It is however to be understood that the feed may contain any suitable lithium concentrations, for example between 1 and 20 g/I, preferably between 5 and 20 WI.
The lithium enriched brine is placed within a precipitation tank for crystallisation and subsequent recovery of the Glauber salt.
The lithium-enriched brine may be cooled to a temperature between -10° C and 33°C, for example between -10°C and 5°C, for example between -5 °C and 5°C to achieve crystallisation of the Glauber salt. Crystallisation of the Glauber salt may occur unaided in the presence of cooling, or with the aid of addition of seed crystals to the lithium enriched brine. The seed crystals may be added batch-wise or at a steady addition rate to the lithium enriched brine.
The seed crystals may be one or more of: sodium sulphate, calcium sulphate or another sulphate salt, or any combination thereof.
The seed crystals may have any suitable particle size distribution to facilitate or aid crystallisation of the Glauber salt. The seed crystals may for example have a dimension of less than 1mm. The seed crystals may for example have a dimension of more than 10km.
Preferably, the seed crystals have a dimension which is in the range of between 10km and 1 mm, preferably between 0.1 p.m and 1 mm.
The seed crystals may be added at any suitable concentration to the lithium enriched brine. Preferably, the seed crystals are added at less than 0.01 to 1% m/m.
Cooling of the precipitation tank may be achieved through one or more of: immersed chilling elements, a jacketed tank system or by placing in a cooled environment.
The lithium enriched brine within the precipitation tank may be unagitated during precipitation/crystallisation of the Glauber salt. In one embodiment, the lithium enriched brine within the precipitation tank may be gently stirred by agitator and/or vibration.
During crystallisation/precipitation, the lithium enriched brine may be left for at least 0.1 hr to obtain a predetermined amount of Glauber salt. Preferably, a period of during crystallisation/precipitation, the lithium enriched brine may be left for up to 24hrs to obtain a predetermined amount of Glauber salt.
The process may further comprise an impurity removal step. The impurity removal step reduces and/or eliminates contamination of the lithium-enriched brine through the addition of one or more impurity removal agents.
Impurity removal agent(s) such as sodium carbonate combined with one or more of calcium carbonate and/or calcium hydroxide is added to the lithium enriched brine, prior to crystallisation/precipitation of the Glauber salt. Addition of these impurity removal agents is done at 1 -3 % m/m for sodium carbonate and 0.01-0.1% m/m for calcium carbonate and/or calcium hydroxide.
The Glauber salt may be recovered from the brine by vacuum or pressure filtration solution. The temperature is preferably maintained below 33°C to prevent melting of the Glauber salt.
After recovery of the Glauber salt, the Glauber salt is heated to evaporate waters of crystallisation.
Preferably, over 65% amount of Glauber salt is recovered where the recovery amount is defined as the molar quantity of Glauber salt recovered as a percentage of the molar quantity of the amount of sodium sulphate used in the calcining process.
The Glauber salt may then be reused as a reagent in the calcining process of lithium mica. This reuse further involves the dewatering of Glauber salt to a temperature between 33°C and 105° to melt the crystals and evaporate waters of hydration. Following partial to complete dehydration of the Glauber salt to return it to pure sodium sulphate, the resultant powder or slurry is mixed with fresh Li mica-containing feed that has not been calcined, additional sodium sulphate, and one or more of calcium hydroxide or calcium carbonate for the calcination process. Preferably, this mixing step may be done on a powder basis ahead of the calcining step. Preferably, this step may include pelletisation of the sodium sulphate and other reagents with the fresh Li mica-containing feed ahead of the calcining step.
The recovered Glauber salt is added to a mixture containing lithium mica and heated for up to 50 minutes at a temperature above 800° C to produce a lithium-enriched brine that also contains a large quantity of sodium of calcium sulphate in solution.
An additional advantage of the recovery and reuse process for Glauber Salt is that any Li lost to the Glauber Salt is re-introduced as a calcining reagent along with the sodium sulphate derived from dehydration of the Glauber Salt.
The present invention therefore provides an economical and efficient process for the recovery of Glauber salt from a lithium enriched brine. Furthermore, the present invention provides an improved, environmentally friendly process, for calcining lithium containing mica using recovered Glauber salt.
EXAMPLES
In the presented example a purified Li brine is derived from calcining of fresh Li mica-containing feed in the presence of sodium sulphate and one of calcium hydroxide and calcium carbonate. This sodium sulphate is added to the fresh Li mica-containing feed at a ratio of 0.7:1 sodium sulphate/Li-mica containing feed on a mass basis, equating to the addition of 906.8 moles of sodium sulphate to a calcining feed batch mass of 183.9kg. After roasting, leaching and impurity removal, the resultant filtered and purified Li-containing brine is cooled to a temperature between -5°C and 5°C, sufficiently cold to crystalise out the sodium sulphate in the form of Glauber salt but still warm enough to prevent formation of ice in this brine. This crystallisation process yields a slurry containing a mixture of solid Glauber salt crystals and a brine further enriched in Li due to waters of hydration being incorporated into the Glauber salt. This slurry is transferred to a filtration unit where the Glauber salt crystals are separated from the Li-enriched brine to allow dehydration of the former and further refining to recover lithium into a saleable form from the latter. This filtration step is carried out with the slurry temperature maintained at a temperature below 33°C to prevent melting of the Glauber salt crystals.
The crystallisation process in the presented example takes 618.6 moles of sodium sulphate out of solution and increases the Li concentration in the brine from 82.4g/I Li to 133.9g/I Li.
The yield of sodium sulphate contained in the Glauber salt as a percentage of the feed that went into the calcining process in this example is 68.2%.
In this example, following separation of the Glauber salt from the Li-enriched brine the solids from the filtration process are heated to a temperature of 60°C to gently evaporate the water of hydration contained in the Glauber salt. This process may be carried out till all water is evaporated and dehydrated sodium sulphate is left for re-use in the calcining process, mixed in as a powder. Alternatively, if the calcining process is based on a pelletised feed, a small quantity of water may be left behind in the sodium sulphate and Glauber salt mixture to aid binding together of the sodium sulphate/Glauber salt/Li mica/calcium carbonate and/or hydroxide mixture.

Claims (15)

  1. CLAIMS1. A process for recovering Glauber salt from magnetic lithium mica material comprising: calcining a magnetic lithium mica-material containing feed in the presence of a sulphate salt and at least one of: lime and/or calcium carbonate to provide a calcined lithium mica-material containing feed; aqueous leaching of the calcined lithium mica-material containing feed at a solids percentage in the slurry of between 5% and 40%, operating at atmospheric pressure and at temperatures between 5°C and 95°C to generate a leached, calcined lithium mica-material and brine; cooling the brine to a predetermined temperature to cause Glauber salt to precipitate to generate lithium-enriched brine; and recovery of the Glauber salt.
  2. 2. A process for calcining magnetic lithium mica material comprising: calcining a magnetic lithium mica-material containing feed in the presence of a sulphate salt and at least one of: lime and/or calcium carbonate to provide a calcined lithium mica-material containing feed; aqueous leaching of the calcined lithium mica-material containing feed at a solids percentage in the slurry of between S% and 40%, operating at atmospheric pressure and at temperatures between 5°C and 95°C to generate a leached, calcined lithium mica-material and brine; cooling the brine to a predetermined temperature to cause Glauber salt to precipitate to generate lithium-enriched brine; recovery of the Glauber salt; and reintroduced the recovered Glauber salt into the step of calcining magnetic lithium mica material.
  3. 3. A process as claimed in either of claims 1 and 2, in which the calcining step(s) comprises heating magnetic lithium mica material in the presence of a sulphate salt and/or Glauber salt.
  4. 4. A process as claimed in any preceding claim, in which the Glauber salt is sodium sulphate decahydrate.
  5. 5. A process as claimed in any preceding claim, in which the cooling step comprises cooling the brine to a temperature of less than 10°C.
  6. 6. A process as claimed in any preceding claim, in which the precipitation step further comprises the addition of a seeding material to the lithium enriched brine to provide nucleation points.
  7. 7. A process as claimed in claim 6, in which the seeding material comprises one or more of: calcium sulphate seed crystals and/or sodium sulphate seed crystals and/or potassium sulphate seed crystals and/or magnesium sulphate seed crystals.
  8. 8. A process as claimed in any preceding claim, in which the process further comprises the addition of one or more hydroxide salt(s) and/or carbonate salt(s) to the brine.
  9. 9. A process as claimed in any preceding claim, in which the lithium mica-material containing feed is a milled feed stream.
  10. 10. A process as claimed in any preceding claim, in which the lithium mica-material containing feed is provided by or formed from igneous rock.
  11. 11. A process as claimed in any preceding claim, in which the lithium mica-material containing feed comprises felsic intrusive rock such as a granite.
  12. 12. A process as claimed in claim 11, in which the felsic intrusive rock is formed during the Variscan Orogeny.
  13. 13. A process as claimed in claim 12, in which the igneous rock forms part of the Cornubian batholith, the Bohemian Batholiths, the Moldanubian Plutonic Complex or the Central French Massif.
  14. 14. A process as claimed in any preceding claim, in which the lithium mica-material containing feed is preferably derived from naturally deposited lithium-mica-bearing sediments or anthropogenically generated waste streams or lithium-mica bearing storage dams derived from naturally deposited lithium-mica-bearing rock or sediments.
  15. 15. A Glauber salt obtained according to a process as claimed in claim 1.
GB2109645.8A 2021-07-02 2021-07-02 Process for the recovery and reuse of sulphate reagents from brines derived from lithium micas Pending GB2608460A (en)

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GB2109645.8A GB2608460A (en) 2021-07-02 2021-07-02 Process for the recovery and reuse of sulphate reagents from brines derived from lithium micas
PCT/EP2022/068229 WO2023275345A2 (en) 2021-07-02 2022-07-01 Processes for the recovery and reuse of sulphate reagents from leach liquors derived from lithium micas

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CN114212808A (en) * 2021-12-20 2022-03-22 江西永兴特钢新能源科技有限公司 Method for preparing battery-grade lithium carbonate by roasting and extracting lithium in tunnel kiln
CN115572820A (en) * 2022-09-27 2023-01-06 宜春银锂新能源有限责任公司 Method for pretreating lepidolite before roasting
CN116119693A (en) * 2023-02-20 2023-05-16 国发新能源科技(江门)有限公司 Technology for preparing lithium carbonate by lepidolite sulfate roasting method
CN116351380B (en) * 2023-03-21 2024-04-12 郑州大学 Low-cost layered lithium ion sieve and preparation method and application thereof

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