The current invention is directed to a method for the production of lithium hydroxide (LiOH) directly from lithium chloride (LiCl), without the need for an intermediate production of lithium carbonate or similar. Specifically, the invention teaches a method of direct production of lithium hydroxide from lithium chloride which contemplates the conversion of LiCl to LiOH from a brine, then crystallizes the LiOH to obtain crude lithium hydroxide monohydrate (LiOH. H2O crude) and then undergoes a second crystallization to produce pure LiOH·H2O. Finally, it is dried and packaged.
The use of lithium in its multiple chemical formulations has taken on a relevant importance in the technological world in recent years. Among the formulations is lithium hydroxide, which is used mainly in the production of lubricating greases capable of operating under extreme temperature and conditions. Approximately 70% of the lubricating greases produced in the world contain lithium. Lithium hydroxide is also used in batteries and dyes. According to the publication from the Chilean Commission on Copper “INTERNATIONAL MARKET FOR LITHIUM AND ITS POTENTIAL IN CHILE,” (Comisiión Chilena del Cobre “MERCADO INTERNACIONAL DEL LITIO Y SU POTENCIAL EN CHILE) from 2017, Lithium is a metal with highly valued properties at present, that has high electrical conductivity, low viscosity, is very light, and has a low coefficient of thermal expansion. These qualities are favorable for multiple applications in the industrial sector, especially in the field of batteries, given the current technological trend. Electromobility driven by environmental campaigns and regulations to reduce the use of fossil fuels, added to the technological development of electronic devices and energy storage systems are the factors pushing up future demand for lithium. The significant growth projected for electric cars using rechargeable batteries as a source of energy has driven the projected demand for lithium, given the higher charge density of lithium-ion batteries and the fact that these have significantly decreased their price. Lithium is usually extracted from brine sources by pumping the brine to the surface to concentrate it in evaporation ponds in a number of solar ponds (conventional method), which finally produce a concentrated lithium chloride (LiCl) solution. This lithium-rich solution is then processed into a chemical plant to produce lithium carbonate or lithium hydroxide. In terms of products, the main lithium compounds marketed and produced are lithium carbonate (Li2CO3), lithium hydroxide monohydrated (LiOH·H2O), and lithium chloride (LiCl), where carbonate accounts for the largest production.
One of the advantages of lithium operations in salt flats have, is that the cost of pumping the brine, concentrating it in evaporation ponds, and further processing it in a chemical plant to obtain lithium carbonate or lithium hydroxide is less than the extraction from hard rocks resources. The latter type of extraction has processes that are similar to those of rock mining involving drilling, blasting, ore concentration, and transportation. With regard to lithium hydroxide (LiOH), it is produced from Lithium Carbonate or Lithium Sulphate, and there are not commercial manufacturing alternatives from Lithium Chloride (LiCl). The process from Li2CO3, makes this material react with slaked lime, Ca (OH)2, producing a solution of LiOH and a solid material of CaCO3 among other impurities. LIOH is separated from CaCO3 by solid-liquid separation stages and is subsequently concentrated and crystallized into its LiOH·H2O (LHM) form. Finally, the LHM crystal is dried to remove the remaining moisture and packaged, thus becoming the final product. One disadvantage of this process is to add the cost of producing Lithium Carbonate (LC) to the cost of producing LiOH. In addition, a final product with a higher carbon footprint is obtained. The method from Li2SO4, makes this material react with NaOH, producing LiOH and Na2SO4·10H2O (Glauber salt), which are separated by fractional crystallization. The LiOH in solution is crystallized to produce crude LiOH·H2O and then is subject to a second crystallization to produce pure LHM. Finally, it is dried and packaged. On the other hand, the Glauber salt is converted into sodium sulfate (Na2SO4) for commercial use through the stages of crystallization, drying, and packaging. Two disadvantages presented by this process are is a higher production cost than the LC method and the production of Na2SO4 that has to be marketed. On the other hand, it is known the attempt to produce LiOH from reacting LiCl and Sodium Hydroxide (NaOH), as our process suggests; however, it is understood that until now there are not successful attempts separating the 2 products produced, LiOH and NaCl, avoiding co-precipitation and contamination of LiOH with NaCl, at industrial stage or commercial plants. In the closest state of the art it is possible to find some variants to try to obtain high purity Lithium Hydroxide by conventional means as well as by electrolysis. Document RU2713360 describes the production of LiOH·H2O from lithium containing sources of poly-component hydro mineral raw material. The Method involves filtration of lithium-bearing brine contaminated with suspended particles with regeneration of filters and processing of spent regenerate and production of productive lithium-bearing brine, extraction from brine of lithium chloride in form of primary concentrate on sorption-desorption modules, nanofiltration cleaning of primary lithium concentrate from magnesium, calcium and sulphate ions. Primary lithium concentrate by reverse-osmotic, electrodialysis concentration, reagent, ion-exchange purification from impurities with subsequent thermal concentration is brought to productive lithium chloride concentrate, which by membrane electrolysis is converted into LiOH solution. LIOH solution is evaporated and LiOH·HO crystallized. This document proposes the conversion of LiCl into LIOH by means of an electrochemical process where, by applying a voltage difference the Lithium cation is separated from its Chlorine anion through the passage through a selective membrane. Once the Lithium went across the membrane it is forced to react with OH ions and is converted into LiOH. The Chlorine ion remains on the other side of the membrane; therefore, it does not mix with LiOH and there is no risk of co-precipitation. In the present invention LiOH is formed by means of a chemical reaction between LiCl and NaOH, then LiOH, and NaCl are formed, being both materials in contact. Therefore, the present invention is based on the separation of these 2 compounds, preventing cross-contamination. This separation occurs by the difference in the concentration and solubility of both materials, and the operating temperature of the process; therefore co-precipitation and contamination of the product is avoided.
Document CL2017-1123 describes a process for producing lithium hydroxide which comprising the following stages:
This application also describes a process for the treatment of lithium chloride, obtained from the brine or spodumene sources, to produce a lithium hydroxide monohydrate product, where the process comprises the stages of:
While the conversion to LIOH uses a theoretical foundation similar to the present invention, i.e., to chemically react LiCl with NaOH, the differentiation lies in the manner of separating the materials produced from NaCl and LiOH. Document CL2017-1123 proposes to separate LiOH from NaCl by means of a melting stage of the mixture of produced solids (NaCl—LiOH) at 500° C. This invention instead performs separation by fractional crystallization where the range of operating temperature, plus the difference in concentrations of the formed materials (NaCl and LIOH) and solubilities of both, NaCl and LiOH at the operating temperature, allows the separation of NaCl and LiOH in the LIOH reaction/crystallization system and in the NaCl system.
The separation method of LiOH from NaCl in the claimed invention represents a significant differentiation from the prior art. Thus, the advantages evidenced by the present invention are appreciated as follows: The production of LiOH from brine resources requires lithium carbonate (LC) as raw material, which is made from LiCl. The present invention proposes direct production of lithium hydroxide from LiCl, avoiding lithium carbonate as raw material. Advantages of the method:
The method of the invention consists of a method for producing lithium hydroxide monohydrate (LiOH·H2O) directly from lithium chloride (LiCl) brine by reaction with sodium hydroxide (NaOH). The method involves the following stages: a) Conversion of LiCl in LiOH. LIOH is produced from the reaction of a LiCl brine, where Li content ranges from 1% to 4% w/w and Li/Na ratio between 2 and 30, with a caustic solution (mother liquor or ML2) containing LiOH, NaOH and other ions. The ML2 is recycled from the stage f of the process and has a temperature between 80° C. and 120° C. b) Crude LiOH crystallization. The LiOH formed in stage a), is fed into a fractional crystallization unit. This unit is operated between 20° C. and 60° C. and with a NaOH content between 10.5% w/w to 0.1% w/w. It produces crude crystals of LiOH·H2O (lithium hydroxide monohydrate), free of sodium chloride. The mother liquor produced, ML1 (liquid separated from the slurry) is sent to stage d). The crystallization of crude LIOH occurs by cooling crystallization. The temperature of the mother liquor from stage f) range from 80° C. to 120° C. c) Recrystallization. The crude lithium hydroxide monohydrate produced in stage b) is dissolved in water and subject to a second crystallization in order to eliminate the remaining impurities in the product. This crystallization occurs at a range between 20° C. and 120° C. The product obtained is high purity lithium hydroxide monohydrate, which is sent to subsequent drying and packaging stages, ready for commercialization.
d) Causticization. The mother liquor (ML1) from stage b) reacts with a NaOH solution and then fed to stage e).
e) NaCl Crystallization. The mixture of ML1 and NaOH from stage d, is subject to a fractional crystallization stage in a temperature range between 80° C. and 120° C., where NaCl is separated from LiOH by crystallization and solid NaCl material is obtained with no co-precipitation of Lithium Hydroxide. This crystallization stage comprises the evaporation of part of the water contained in the mixture of ML1 and NaOH solution.
f) Separation of NaCl and ML2. The solid-liquid mixture formed in stage e) is fed to a separation process where a Mother Liquor 2 (ML2) is generated and separated from the sodium chloride (NaCl) crystals. The ML2 is sent to stage a) as a hydroxide source and the solid NaCl is ready for final disposal.
The liquid that is separated from the slurry in the crystallization stage of LiOH is the Mother Liquor 1 (ML1).
Its chemical composition as follows:
At crystallization stage of LiOH (stage b) impurities tend to concentrate, so a purge of the mother liquor can be carried out to reduce the accumulation of impurities and thus avoid contaminants in the final product. The Mother Liquor 2 (ML2) produced in stage f) of NaCl crystallization, where ML2 is generated by separating the NaCl crystals from the liquid and is sent to stage a) as a hydroxide source, has the following characteristics:
At the NaCl crystallization stage (e) or NaCl separation stage (f) from ML2, a purge is also possible to prevent the accumulation of impurities in the final product.
In one preferred embodiment the method comprises the stages: a) LiCl conversion into LiOH and b) of crystallization of LiOH, are carried out simultaneously, this means in a single stage where the chemical reaction of the conversion of LiCl to LIOH and the phenomenon of crystallization of LIOH occur in a single reactor in a similarly simultaneous way. In preferred embodiment, the stages d) of caustisization, and e) of NaCl crystallization occur simultaneously, that is, caustisization and crystallization in a single reactor.
During the tests carried out for the application of the method it was found that data collected from the solubility tests showed that LiOH and NaCl become less soluble as the concentration of NaOH increases. Relative decrease in solubility of NaCl was shown to be greater than that of LIOH. Based on these data, 5% NaOH proves to be very useful for the crystallization operation of lithium hydroxide monohydrate at 35° C. and 10% NaOH for the crystallization operation of sodium chloride at 100° C. For LIOH crystallization stage, at those operating conditions of temperature and concentration, it is verified that NaCl and LIOH are kept in solution; therefore, an increase in the concentration of Li+ and OH− ions up to the point of reaching LiOH saturation allows to achieve its crystallization or precipitation avoiding NaCl saturation and precipitation, as its concentration was not modified. The same principle is applied for the crystallization of NaCl and its separation from LIOH in solution. The purity of the lithium hydroxide monohydrate and sodium chloride crystals increased over time as the test progressed and less mother liquor was retained in the crystals. The amount of mother liquor retained in the lithium hydroxide monohydrate crystals decreased from 25% to 7.9% and from 7.6% to 4.2% in the sodium chloride crystals.
Although the caustisization stage contemplates that the mother liquor (ML1) from Stage b) reacts with a NaOH solution, preferably 50% by weight, it is also possible to carry out caustisization with a NaOH solution at different NaOH contents. During the crystallization stage of NaCl, it was evident that the solids contained both sodium chloride and lithium hydroxide; however, by adding less caustic solution and decreasing evaporation, the sodium chloride was successfully crystallized with no co-precipitation of Lithium Hydroxide. Particularly, in a first test the lithium hydroxide crystallization stage was carried out at 35° C. At the beginning of the test, excess LiOH·H2O was added and NaCl solids were added to ensure that the feed was saturated. Each solubility point varied in the amount of NaOH, and was allowed to mix for 45 minutes before sample collection. The five mother liquor samples were chemically analyzed and the results are shown in the table below:
In a second test, the crystallization stage of lithium hydroxide, was performed at a temperature of 35° C. and an excess concentration of NaOH between 0.5% and 4%. At the beginning of the test, an excess of LIOH·H2O and NaCl solids was added to ensure that the mother liquor was saturated. Each solubility point varied in the amount of NaOH and was allowed to mix for 45 minutes before sample collection. The five mother liquor samples were chemically analyzed and the results are shown in the table below:
Regarding the sodium chloride crystallization test, it was performed at 100° C. and an excess of NaOH concentration between 3% and 10%. At the beginning of the test, an excess of LiOH·H2O and NaCl solids was added to ensure that the liquor was saturated. Each solubility point varied in the amount of NaOH and was allowed to mix for 45 minutes before sample collection. The five mother liquor samples were chemically analyzed and the results are shown in the table below:
Based on the solubility tests indicated above, the process was carried out in a continuous state, which yielded the following results: Chemical analysis of lithium hydroxide mother liquor 35° C.
Chemical analysis of washed and unwashed LiOH·H2O solids at 35° C.
Chemical analysis of the mother liquor of sodium chloride 100° C.:
Chemical analysis of sodium chloride solids at 100° C.:
Filing Document | Filing Date | Country | Kind |
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PCT/CL2021/050003 | 1/5/2021 | WO |