Patent Application
20240175157
Conventional lithium extraction methods from ores, such as spodumene, involve chemical and pyro-metallurgical processes. These methods are generally inefficient and generate significant waste. Meanwhile, aluminum extraction from bauxite relies on slightly more efficient processes, such as the Bayer process to produce alumina and the Hall-Héroult electrolytic process to obtain aluminum metal.
There is a growing need for improved electrolytic methods for lithium extraction and purification that are more economically productive, less wasteful, and environmentally friendly. Such methods for lithium extraction should ideally be comparable to the Hall-Héroult and Hoopes processes used in aluminum production, which allows for improved lithium extraction from lithium-containing ores and recycled batteries.
Provided herein is a method comprising: (a) contacting a source of lithium with a molten metal; (b) extracting lithium from the source of lithium and transferring the lithium to the molten metal, thereby forming a lithium-rich molten metal alloy; and (c) transferring the lithium from the lithium-rich molten metal alloy to a conductive substrate. In some embodiments, the source of lithium comprises a borate melt. In some embodiments, the method further comprises, before (a), dissolving material comprising lithium ions in the borate melt. In some embodiments, the material comprising lithium ions comprises a lithium ore. In some embodiments, the lithium ore comprises spodumene. In some embodiments, the borate melt comprises a fluoride salt. In some embodiments, the fluoride salt is selected from the group consisting of NaF, KF, CaF2, and combinations thereof. In some embodiments, the molten metal has a higher density than the borate melt.
In some embodiments, (b) comprises applying a voltage across an anode and the molten metal. In some embodiments, the method further comprises, before (c), contacting the lithium-rich molten metal alloy with a molten salt electrolyte. In some embodiments, (c) comprises applying a voltage across a cathode and the lithium-rich molten metal alloy, causing lithium ions to be released from the lithium-rich molten metal alloy and reduced to lithium metal at the cathode.
In some embodiments, the borate melt is maintained at a temperature between 600° C. and 1000° C. In some embodiments, (c) is performed at a temperature between 300° C. and 800° C.
In some embodiments, the cathode comprises an inert material. In some embodiments, the cathode comprises nickel, copper, titanium, and carbon (graphite).
In some embodiments, the molten salt electrolyte comprises a salt selected from the group consisting of lithium halides, sodium halides, potassium halides, and combinations thereof. In some embodiments, the molten salt electrolyte comprises a salt selected from the group consisting of LiCl, KCl, RbCl, CsCl, SrCl2, BaCl2, and combinations thereof. In some embodiments, the molten salt electrolyte comprises fluoride salts. In some embodiments, the fluoride salts are selected from the group consisting of LiF, CaF2, and combinations thereof.
In some embodiments, (a) and (b) are carried out in a first cell, and (c) is carried out in a second cell that is different from the first cell. In some embodiments, the method is used for a scale-up production.
In a certain aspect, this disclosure provides a system comprising a first cell comprising: a source of lithium and a molten metal, and a second cell comprising: a molten salt electrolyte and a conductive substrate. In some embodiments, the molten metal is configured to receive lithium from the source of lithium to form a lithium-rich molten metal alloy. In some embodiments, the lithium-rich molten metal alloy is moved from the first cell to the second cell after it is formed. In some embodiments, the lithium is transferred from the lithium-rich molten metal alloy to the conductive substrate to form a lithium metal layer.
In some embodiments, the source of lithium comprises a borate melt that material comprising lithium ions is dissolved in. In some embodiments, the material comprising lithium ions comprises lithium ore. In some embodiments, the lithium ore comprises spodumene. In some embodiments, the borate melt comprises a fluoride salt. In some embodiments, the fluoride salt is selected from the group consisting of NaF, KF, CaF2, and combinations thereof.
In some embodiments, the molten metal is denser than the borate melt. In some embodiments, the first cell further comprises an anode, wherein a voltage is applied between the anode and the molten metal to form the lithium-rich molten metal alloy.
In some embodiments, the anode in the first cell comprises carbon. In some embodiments, the conductive substrate is a cathode. In some embodiments, the cathode is an inert material. In some embodiments, the cathode comprises nickel, copper, titanium, and carbon (graphite).
In some embodiments, a voltage is applied across the cathode and the lithium-rich molten metal alloy to extract lithium ions from the lithium-rich molten metal alloy and to form a lithium metal layer.
In some embodiments, the borate melt comprises a fluoride salt. In some embodiments, the fluoride salt comprises NaF, KF, CaF2, and combinations thereof.
In some embodiments, the first cell is kept at a temperature between 600 and 1000° C. In some embodiments, the second cell is kept at a temperature between 300 and 800° C.
In some embodiments, the molten salt electrolyte comprises salts selected from the group consisting of lithium halides, sodium halides, potassium halides, and combinations thereof. In some embodiments, the molten salt electrolyte comprises salts selected from the group consisting of LiCl, KCl, RbCl, CsCl, SrCl2, BaCl2, and combinations thereof. In some embodiments, the molten salt electrolyte comprises fluoride salts. In some embodiments, the fluoride salts are selected from the group consisting of LiF, CaF2, and combinations thereof.
In accordance with one embodiment of the disclosure, lithium is extracted from a lithium ion containing material by a process that includes the steps of:
According to some embodiments of the process, the lithium ion containing material is a lithium ore. In some embodiments, the lithium ore includes spodumene.
In some embodiments the anode in the first cell includes carbon. In some embodiments the borate melt includes a fluoride. In some embodiments the fluoride is selected from the group consisting of NaF, KF, CaF2, and combinations thereof.
According to some embodiments of the process, the first cell is kept at a temperature between 600 and 1000° C. According to some embodiments, the second cell is kept at a temperature between 300 and 800° C.
According to some embodiments, the cathode immersed in the molten salt electrolyte is an inert material. In some embodiments the cathode includes a material selected from the group consisting of nickel, copper, titanium, and carbon (graphite). In some embodiments, the molten salt electrolyte includes salts selected from the group consisting of lithium halides, sodium halides, potassium halides, and combinations thereof. In some embodiments the molten salt electrolyte includes salts selected from the group consisting of LiCl, KCl, RbCl, CsCl, SrCl2, BaCl2, and combinations thereof. In some embodiments the molten salt electrolyte includes fluoride salts. The fluoride salts may include LiF, CaF2, and combinations thereof.
Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
The foregoing features of embodiments will be more readily understood by reference to the following detailed description, taken with reference to the accompanying drawings, in which:
Unless defined otherwise, all terms of art, notations and other technical and scientific terms or terminology used herein are intended to have the same meaning as is commonly understood by one of ordinary skill in the art to which the claimed subject matter pertains. In some cases, terms with commonly understood meanings are defined herein for clarity and/or for ready reference, and the inclusion of such definitions herein should not necessarily be construed to represent a substantial difference over what is generally understood in the art.
Throughout this application, various embodiments may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.
As used in the specification and claims, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “a sample” includes a plurality of samples, including mixtures thereof.
Whenever the term “at least,” “greater than,” or “greater than or equal to” precedes the first numerical value in a series of two or more numerical values, the term “at least,” “greater than” or “greater than or equal to” applies to each of the numerical values in that series of numerical values. For example, greater than or equal to 1, 2, or 3 is equivalent to greater than or equal to 1, greater than or equal to 2, or greater than or equal to 3.
The expressions “at least about A, B, and C” and “at least about A, B, or C” may be construed to mean at least about A, at least about B, or at least about C. The expressions “at most about A, B, and C” and “at most about A, B, or C” may be construed to mean at most about A, at most about B, or at most about C.
The expression “between about A and B, C and D, and E and F” may be construed to mean between about A and about B, between about C and about D, and between about E and about F. The expression “between about A and B, C and D, or E and F” may be construed to mean between about A and about B, between about C and about D, or between about E and about F.
As used herein, the term “about” a number refers to that number plus or minus 10% of that number. The term “about” a range refers to that range minus 10% of its lowest value and plus 10% of its greatest value.
The section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.
A “cathode” is an electrode where reduction occurs.
An “anode” is an electrode where oxidation occurs.
The term “spodumene” refers to a lithium aluminum silicate mineral with the chemical formula LiAl(SiO3)2 and is the dominant lithium ore and one of the primary sources of lithium. Spodumene is typically found in granitic pegmatites, a type of rock that forms from slowly cooling magma deep within the Earth's crust. There are two main crystalline forms of spodumene: alpha-spodumene and beta-spodumene. Alpha-spodumene is the more common, naturally occurring form, while beta-spodumene forms when alpha-spodumene is heated to high temperatures (above 900° C.). Beta-spodumene is more reactive and easier to process for lithium extraction than the alpha form.
A “fluoroborate melt” is a molten mixture of borate salts and fluoride salts. It refers to a mixture of fluoroborate compounds in their liquid or molten state. Fluoroborates are compounds that contain boron, fluorine, and other elements. They are a subclass of the larger borate family but have a distinct chemical composition featuring the BF4− anionic group.
“Borate salts” are salts with oxyborate anions.
The term “borate melt” refers to a mixture of borate compounds in their liquid/molten state. Borates are compounds that contain boron and oxygen, typically in the form of the BO3 or BO4 anionic groups. Examples of common borates include borax (Na2B4O7·10H2O), boric acid (H3BO3), and lithium borate (Li2B4O7).
“Oxyborate anions” are anions with chemical formula of BxOyn-, where x, y, and n are positive integers not equal to zero. Common oxyborate anions include BO33-, B4O72-, and B2O42-.
The term “molten salt electrolyte” refers to a type of electrolyte that consist of salt compounds in a liquid or molten state. They are essential components in electrochemical processes, including batteries, fuel cells, and various other applications. Molten salt electrolytes are formed by heating solid salts to high temperatures until they melt, turning into a liquid form. These high temperatures allow ions in the salt to move more freely, facilitating ionic conductivity. According to some embodiments of this disclosure, the molten salt electrolyte includes at least one ionic species having a higher reduction potential than Li+. According to some embodiments, the molten salt electrolyte comprises one or more salts selected from the group consisting of aluminum salts, titanium salts, alkali metal salts, alkaline earth metal salts, ammonium salts, and combinations thereof. In some embodiments, the molten salt electrolyte comprises aluminum salts. In some embodiments, the aluminum salts comprises aluminum chloride. In some embodiments, the molten salt electrolyte comprises anions chosen from the group consisting of halides, nitrates, nitrites, sulfates, sulfites, carbonates, hydroxides and combinations thereof.
In some embodiments, the molten salts may comprise solutions of AlCF, and may include LiCl, NaCl, and KCl. Some such embodied chloroaluminate molten salt electrolytes can operate at temperatures at or near the boiling point of water.
The molten salt electrolytes disclosed herein are non-flammable. Because these inorganic molten salt electrolytes operate at temperatures well below the melting point of lithium, they are not significantly corrosive, and there is no danger from the leakage of molten lithium.
An example of the disclosed method involves two electrochemical stages, as summarized in
In some embodiments, the lithium ore or other lithium ion containing material of stage one includes, but not limited to spodumene (LiAlSi2O6), lepidolite (K(Li,Al,Rb)2(Al,Si)4O10(F,OH)2), petalite (LiAlSi4O10), lithium brines, hectorite clay (Na0.3(Mg,Li)3Si4O10(OH)2), geothermal brines, or recycled lithium-ion batteries.
In some embodiments, the borate melt 10 includes borate salts chosen from the group consisting of sodium salts, potassium salts, calcium salts, magnesium salts, and combinations thereof. In some embodiments, the borate melt includes fluoride salts. In some embodiments, the fluoride salts are chosen from the group consisting of NaF, KF, CaF2, MgF2, and combinations thereof. The borate melt 10 may be capable of breaking down the lithium ore structure by dissolving metal oxides, including lithium oxide (Li2O) present in the ore. The metal fluoride components may improve the solubility of the lithium compounds in the borate melt. In some embodiments, the temperature of the borate melt 10 is between 850 and 950 degrees centigrade. In some embodiments, the temperature of the borate melt 10 is higher than about 700° C., 750° C., 800° C., 850° C., 900° C., 950° C., or 1000° C. In some embodiments, the temperature of the borate melt 10 is lower than about 700° C., 750° C., 800° C., 850° C., 900° C., 950° C., or 1000° C. In some embodiments, the temperature of the borate melt 10 is between about 700° C. and 1000° C., between about 750° C. and 950° C., between about 800° C. and 900° C., or between about 850° C. and 1000° C. In some embodiments, after the lithium ore is dissolved in the borate melt containing the metal fluoride, the melt may be cooled and solidified.
In some embodiments, the layer of molten metal 30 of stage one includes a metal selected from the group consisting of Al, Sn, Pb, Bi, Sb, Zn, and alloys of the same. In some embodiments, the layer of molten metal includes Sn. In some embodiments, the layer of molten metal includes an alloy of Pb and Sb.
In some embodiments, the anode 40 of stage one includes carbon, so that as lithium ion is reduced at the layer of molten metal 30, forming a lithium-containing alloy, carbon at the anode 40 is oxidized to CO2 or CO, which is released as a gas. In some embodiments, the anode electrode 40 comprises graphite, platinum (Pt), titanium (Ti), or a combination thereof.
In some embodiments, when a current 50 is applied across the anode 40 and the layer of molten metal 30, the molten metal may selectively extract lithium from a lithium-containing source, such as a borate melt with lithium salts. In some embodiments, lithium may be soluble in the molten metals, resulting in the formation of a lithium-rich molten metal alloy. In some embodiments, the lithium-rich molten metal alloy comprises lithium of at least about 0.1 weight % (wt %), 0.2 wt %, 0.4 wt %, 0.6 wt %, 0.8 wt %, 1 wt %, 2 wt %, 4 wt %, 6 wt %, 8 wt %, 10 wt %, 12 wt %, 14 wt %, 16 wt %, 18 wt %, 20 wt %, 22 wt %, 24 wt %, 26 wt %, 28 wt %, 30 wt %, 32 wt %, 34 wt %, 36 wt %, 38 wt %, 40 wt %, 42 wt %, 44 wt %, 46 wt %, 48 wt %, 50 wt %, 52 wt %, 54 wt %, 56 wt %, 58 wt %, or 60 wt % relative to a total weight of the lithium-rich molten metal alloy. In some embodiments, the lithium-rich molten metal alloy comprises lithium of at most about 0.1 weight % (wt %), 0.2 wt %, 0.4 wt %, 0.6 wt %, 0.8 wt %, 1 wt %, 2 wt %, 4 wt %, 6 wt %, 8 wt %, 10 wt %, 12 wt %, 14 wt %, 16 wt %, 18 wt %, 20 wt %, 22 wt %, 24 wt %, 26 wt %, 28 wt %, 30 wt %, 32 wt %, 34 wt %, 36 wt %, 38 wt %, 40 wt %, 42 wt %, 44 wt %, 46 wt %, 48 wt %, 50 wt %, 52 wt %, 54 wt %, 56 wt %, 58 wt %, 60 wt %, 62 wt %, 64 wt %, 66 wt %, 68 wt %, or 70 wt % relative to a total weight of the lithium-rich molten metal alloy.
In some embodiments, the potential applied across the anode 40 and the layer of molten metal 30 is at least about 3V, 4V, 5V, 6V, 7V, 8V, 9V, 10V, 11V, or 12V. In some embodiments, the potential applied across the anode 40 and the layer of molten metal 30 is at most about 3V, 4VV, 6V, 7V, 8V, 9V, 10V, 11V, or 12V. In some embodiments, the potential applied across the anode 40 and the layer of molten metal 30 is about 3V to 12V, 4V to 9V, 5V to 8V, or 6V to 7V.
In some embodiments, an amount of the lithium transferred from the borate melt to the molten metal comprises at least about 0.1 mg/hr, 0.5 mg/hr, 1 mg/hr, 5 mg/hr, 10 mg/hr, 50 mg/hr, 100 mg/hr, 150 mg/hr, 200 mg/hr, 250 mg/hr, 300 mg/hr, 350 mg/hr, 400 mg/hr, 450 mg/hr, 500 mg/hr, 550 mg/hr, 600 mg/hr, 650 mg/hr, 700 mg/hr, 750 mg/hr, 800 mg/hr, 850 mg/hr, 900 mg/hr, 950 mg/hr, 1,000 mg/hr, 1,200 mg/hr, 1,400 mg/hr, 1,600 mg/hr, 1,800 mg/hr, 2,000 mg/hr, 2,500 mg/hr, 3,000 mg/hr, 3,500 mg/hr, 4,000 mg/hr, 4,500 mg/hr, 5,000 mg/hr, 5,500 mg/hr, 6,000 mg/hr, 6,500 mg/hr, 7,000 mg/hr, 7,500 mg/hr, 8,000 mg/hr, 8,500 mg/hr, 9,000 mg/hr, 9,500 mg/hr, 10,000 mg/hr, 20,000 mg/hr, 30,000 mg/hr, 40,000 mg/hr, 50,000 mg/hr, 60,000 mg/hr, 70,000 mg/hr, 80,000 mg/hr, 90,000 mg/hr, 100,000 mg/hr, 110,000 mg/hr, or 120,000 mg/hr. In some embodiments, an amount of the lithium transferred from the borate melt to the molten metal comprises at most about 0.1 mg/hr, 0.5 mg/hr, 1 mg/hr, 5 mg/hr, 10 mg/hr, 50 mg/hr, 100 mg/hr, 150 mg/hr, 200 mg/hr, 250 mg/hr, 300 mg/hr, 350 mg/hr, 400 mg/hr, 450 mg/hr, 500 mg/hr, 550 mg/hr, 600 mg/hr, 650 mg/hr, 700 mg/hr, 750 mg/hr, 800 mg/hr, 850 mg/hr, 900 mg/hr, 950 mg/hr, 1,000 mg/hr, 1,200 mg/hr, 1,400 mg/hr, 1,600 mg/hr, 1,800 mg/hr, 2,000 mg/hr, 2,500 mg/hr, 3,000 mg/hr, 3,500 mg/hr, 4,000 mg/hr, 4,500 mg/hr, 5,000 mg/hr, 5,500 mg/hr, 6,000 mg/hr, 6,500 mg/hr, 7,000 mg/hr, 7,500 mg/hr, 8,000 mg/hr, 8,500 mg/hr, 9,000 mg/hr, 9,500 mg/hr, 10,000 mg/hr, 20,000 mg/hr, 30,000 mg/hr, 40,000 mg/hr, 50,000 mg/hr, 60,000 mg/hr, 70,000 mg/hr, 80,000 mg/hr, 90,000 mg/hr, 100,000 mg/hr, 110,000 mg/hr, or 120,000 mg/hr.
The molten salt of the second stage is formulated to be liquid at the operating temperature of the cell. In some embodiments, the temperature of the molten salt of the second stage is between about 300° C. and about 800° C. In some embodiments, the temperature of the molten salt of the second stage is higher than about 200° C., 250° C., 300° C., 350° C., 400° C., 450° C., 500° C., 550° C., 600° C., 650° C., 700° C., 750° C., 800° C., 850° C., or 900° C. In some embodiments, the temperature of the molten salt of the second stage is lower than about 200° C., 250° C., 300° C., 350° C., 400° C., 450° C., 500° C., 550° C., 600° C., 650° C., 700° C., 750° C., 800° C., 850° C., or 900° C. In some embodiments, the temperature of the molten salt of the second stage is between about 200° C. and 900° C., between about 250° C. and 850° C., between about 300° C. and 800° C., between about 350° C. and 750° C., between about 400° C. and 700° C., between about 450° C. and 650° C., between about 500° C. and 600° C., or between about 550° C. and 750° C.
In some embodiments, the molten salt includes, but not limited to LiCl, KCl, RbCl, CsCl, SrCl2, BaCl2, and combinations thereof. In some embodiments, the molten salt formulation comprises fluoride salts. In some embodiments the molten salt formulation comprises fluoride salts with highly cathodic decomposition potentials. In some such embodiments, the fluoride salts include, but not limited to LiF, CaF2, and combinations thereof. In some embodiments, the molten salt electrolyte is free of oxides. In some embodiments, the molten salt electrolyte has the molten salt electrolyte may have small (trace) amounts of oxides present. In some embodiments, the method disclosed herein may work with small (trace) amounts of oxides present. In some embodiments, the molten salt electrolyte may comprise oxides of at least about 0.01 wt % to about 5 wt %. In some embodiments, the molten salt electrolyte may comprise oxides of at most about 0.01 wt % to about 5 wt %.
In preferred embodiments, the molten salt is formulated to be a liquid at the desired operating temperature. In some embodiments, the melting temperature of the molten salt electrolyte is higher than about 100° C., 95° C., 90° C., 85° C., 80° C., 75° C., 70° C., 65° C., 60° C., 55° C., 50° C., 45° C., 40° C., 35° C. or 30° C. In some embodiments, the melting temperature of the molten salt electrolyte is higher than about 100° C. In some embodiments, the melting temperature of the molten salt electrolyte is higher than about 75° C. In some embodiments, the melting temperature of the molten salt electrolyte is higher than about 50° C. In some embodiments the melting temperature of the molten salt electrolyte is higher than about 30° C. In some embodiments, the melting temperature of the molten salt electrolyte is lower than about 100° C., 95° C., 90° C., 85° C., 80° C., 75° C., 70° C., 65° C., 60° C., 55° C., 50° C., 45° C., 40° C., 35° C. or 30° C. In some embodiments, the melting temperature of the molten salt electrolyte is lower than about 100° C. In some embodiments, the melting temperature of the molten salt electrolyte is lower than about 75° C. In some embodiments, the melting temperature of the molten salt electrolyte is lower than about 50° C. In some embodiments the melting temperature of the molten salt electrolyte is lower than about 30° C.
In some embodiments, for the second stage, the cathode is a conductive substrate. In some embodiments, the cathode comprises a current collector. In some embodiments, the current collector comprises carbonaceous material, Ti, Al, Cu, Ni, stainless steel, or combinations thereof. In some embodiments, the cathode comprises a metal current collector. In some embodiments, the cathode comprises a carbon current collector. In some embodiments, the cathode comprises a lithium absorption electrode comprising graphite or metals that alloy with lithium. In some embodiments, the cathode comprises an electrically conductive slurry comprising an electrically conductive additive.
In some embodiments, the potential applied across the cathode 80 and the alloy of molten metal and lithium is at least about 3V, 4V, 5V, 6V, 7V, 8V, 9V, 10V, 11V, or 12V. In some embodiments, the potential applied across the cathode 80 and the alloy of molten metal and lithium is at most about 3V, 4VV, 6V, 7V, 8V, 9V, 10V, 11V, or 12V. In some embodiments, the potential applied across the cathode 80 and the alloy of molten metal and lithium is about 3V to 12V, 4V to 9V, 5V to 8V, or 6V to 7V.
In some embodiments, an amount of the lithium transferred from the alloy of molten metal and lithium to the cathode comprises at least about 0.1 mg/hr, 0.5 mg/hr, 1 mg/hr, 5 mg/hr, 10 mg/hr, 50 mg/hr, 100 mg/hr, 150 mg/hr, 200 mg/hr, 250 mg/hr, 300 mg/hr, 350 mg/hr, 400 mg/hr, 450 mg/hr, 500 mg/hr, 550 mg/hr, 600 mg/hr, 650 mg/hr, 700 mg/hr, 750 mg/hr, 800 mg/hr, 850 mg/hr, 900 mg/hr, 950 mg/hr, 1,000 mg/hr, 1,200 mg/hr, 1,400 mg/hr, 1,600 mg/hr, 1,800 mg/hr, 2,000 mg/hr, 2,500 mg/hr, 3,000 mg/hr, 3,500 mg/hr, 4,000 mg/hr, 4,500 mg/hr, 5,000 mg/hr, 5,500 mg/hr, 6,000 mg/hr, 6,500 mg/hr, 7,000 mg/hr, 7,500 mg/hr, 8,000 mg/hr, 8,500 mg/hr, 9,000 mg/hr, 9,500 mg/hr, 10,000 mg/hr, 20,000 mg/hr, 30,000 mg/hr, 40,000 mg/hr, 50,000 mg/hr, 60,000 mg/hr, 70,000 mg/hr, 80,000 mg/hr, 90,000 mg/hr, 100,000 mg/hr, 110,000 mg/hr, or 120,000 mg/hr. In some embodiments, an amount of the lithium transferred from the alloy of molten metal and lithium to the cathode comprises at most about 0.1 mg/hr, 0.5 mg/hr, 1 mg/hr, 5 mg/hr, 10 mg/hr, 50 mg/hr, 100 mg/hr, 150 mg/hr, 200 mg/hr, 250 mg/hr, 300 mg/hr, 350 mg/hr, 400 mg/hr, 450 mg/hr, 500 mg/hr, 550 mg/hr, 600 mg/hr, 650 mg/hr, 700 mg/hr, 750 mg/hr, 800 mg/hr, 850 mg/hr, 900 mg/hr, 950 mg/hr, 1,000 mg/hr, 1,200 mg/hr, 1,400 mg/hr, 1,600 mg/hr, 1,800 mg/hr, 2,000 mg/hr, 2,500 mg/hr, 3,000 mg/hr, 3,500 mg/hr, 4,000 mg/hr, 4,500 mg/hr, 5,000 mg/hr, 5,500 mg/hr, 6,000 mg/hr, 6,500 mg/hr, 7,000 mg/hr, 7,500 mg/hr, 8,000 mg/hr, 8,500 mg/hr, 9,000 mg/hr, 9,500 mg/hr, 10,000 mg/hr, 20,000 mg/hr, 30,000 mg/hr, 40,000 mg/hr, 50,000 mg/hr, 60,000 mg/hr, 70,000 mg/hr, 80,000 mg/hr, 90,000 mg/hr, 100,000 mg/hr, 110,000 mg/hr, or 120,000 mg/hr.
In some embodiments, when a current 90 is applied across the cathode 80 and the alloy of molten metal and lithium, Li+ is released from the alloy and reduced to form a layer of lithium metal 100 at the cathode 80. In some embodiments, a thickness of the lithium metal layer on the cathode may be at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 μm. In some embodiments, a thickness of the lithium metal layer on the cathode may be at least about 1, 5, 10, 20, 30, 40, 50, 100, 200, 300, 400, or 500 μm. In some embodiments, a thickness of the lithium metal layer on the cathode may be at most about 1, 5, 10, 20, 30, 40, 50, 100, 200, 300, 400, or 500 μm. In some embodiments, a thickness of the lithium metal layer on the cathode may be about between 1 and 380 μm, between 1 and 370 μm, between 1 and 360 m, between 1 and 350 μm, between 1 and 340 μm, between 1 and 330 μm, between 1 and 320 μm, between 1 and 310 μm, between 1 and 300 μm, between 1 and 250 μm, between 1 and 200 μm, between 1 and 150 μm, between 1 and 100 μm, between 1 and 90 μm, between 1 and 80 μm, between 1 and 70 μm, between 1 and 60 μm, between 1 and 50 μm, between 1 and 45 μm, between 1 and 40 μm, between 1 and 35 μm, between 1 and 30 μm, between 1 and 25 μm, between 1 and 20 μm, between 1 and 15 μm, between 1 and 10 μm, or between 1 and 5 μm.
In some embodiments, the density of the lithium metal deposited ranges from about 0.2 g/cm3 to 0.534 g/cm3. In some embodiments, the density of the lithium metal deposited is at least about 0.2, 0.22, 0.24, 0.26, 0.28, 0.3, 0.32, 0.34, 0.36, 0.38, 0.4, 0.42, 0.44, 0.46, 0.48, 0.5, 0.52, or 0.534 g/cm3. In some embodiments, the density of the lithium metal deposited is at most about 0.2, 0.22, 0.24, 0.26, 0.28, 0.3, 0.32, 0.34, 0.36, 0.38, 0.4, 0.42, 0.44, 0.46, 0.48, 0.5, 0.52, or 0.534 g/cm3.
As embodied in
In some embodiments, the method disclosed herein may be used for a scale-up production.
The embodiments of the disclosure described above are intended to be merely exemplary; numerous variations and modifications will be apparent to those skilled in the art. All such variations and modifications are intended to be within the scope of the present disclosure as defined in any appended claims.
The following list of embodiments of the invention are to be considered as disclosing various features of the invention, which features can be considered to be specific to the particular embodiment under which they are discussed, or which are combinable with the various other features as listed in other embodiments. Thus, simply because a feature is discussed under one particular embodiment does not necessarily limit the use of that feature to that embodiment.
Embodiment 1. A process for extracting lithium from a lithium ion containing material comprising the steps of.
This application claims priority to U.S. Provisional Application No. 63/428,546 filed Nov. 29, 2022, which is entirely incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63428546 | Nov 2022 | US |
