Lithium Sulfate Monohydrate Concentration from High-Sulfate Brines

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Solution Overview

Problem

Existing processes are unable to economically process high sulfate brines to produce lithium sulfate monohydrate due to high impurity levels of chlorine and magnesium, making them financially unattractive for lithium production.

Innovation Solution

A three-stage process involving grinding, flotation, and leaching is employed to concentrate lithium sulfate monohydrate with low impurity contents, utilizing a selective concentration stage to enhance purity and recovery, followed by a leaching stage to achieve over 95% purity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If high sulfate brines are processed using conventional methods, then lithium production can be achieved, but the impurity levels of chlorine and magnesium become too high, making the process financially unattractive

Engineering Contradiction:

Improvelithium sulfate monohydrate concentrationVSAvoidimpurity levels (chlorine and magnesium)

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The flotation process is divided into multiple stages: rougher flotation to remove coarse impurities, cleaner flotation to further purify the concentrate, and scavenger flotation to recover additional lithium. This segmented approach progressively reduces chlorine and magnesium impurity levels while concentrating lithium sulfate monohydrate, making the brine economically viable for lithium production

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The process selectively extracts lithium sulfate monohydrate from the complex brine mixture containing high levels of chlorine and magnesium impurities. Through controlled flotation conditions and selective reagents, lithium is separated and concentrated while leaving harmful impurities in the tailings, achieving over 95% purity in the final product

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If selective concentration stages are added to enhance purity, then lithium sulfate monohydrate purity increases to over 95%, but the process complexity increases

Engineering Contradiction:

Improvelithium sulfate monohydrate purityVSAvoidprocess stages and equipment

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Multiple flotation operations (rougher, cleaner, and scavenger stages) are combined into an integrated flow sheet that processes the brine systematically. The merging of these stages achieves high purity (over 95%) through progressive concentration while managing complexity through unified process control and coordinated reagent application across all stages

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If conventional flotation methods are used on high sulfate brines, then processing can proceed, but the recovery rate of lithium is insufficient and impurities remain high

Engineering Contradiction:

Improvelithium recovery rateVSAvoidimpurity content in concentrate

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The rougher flotation stage performs preliminary separation by removing coarse impurities and concentrating lithium sulfate monohydrate before the cleaner stages. This preliminary action prepares the material for subsequent high-purity concentration steps, ensuring both high recovery rates and low impurity content in the final product

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Different flotation stages use locally optimized conditions and reagents tailored to specific purification needs. The rougher stage uses conditions optimized for high recovery, while cleaner stages use conditions optimized for high purity. This local quality approach allows each stage to perform its specific function effectively, achieving both high productivity and low impurity content

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The process effectively concentrates lithium sulfate monohydrate to over 95% purity, addressing the financial unattractiveness of high sulfate brines by enhancing recovery and reducing impurities.

Implementation Method 1

flotation, and leaching is employed to concentrate lithium sulfate monohydrate with low impurity contents

Methodology Applied

Scientific EffectFlotation: Froth Floatation

Implementation Method 2

followed by a leaching stage to achieve over 95% purity

Methodology Applied

Scientific EffectLeaching: Solvation

Data Source

PatentUS20260028696A1Global process for obtaining lithium sulfate monohydrate ore with low contents of impurities associated with chlorine and magnesium

Publication Date: 2026.01.29 SOC QUIMICA Y MINERA DE CHILE

AI summary

This patent application refers to a global process to obtain lithium sulfate monohydrate ore with low contents of impurities associated to chlorine and magnesium; in particular, the process consists of the concentration, through grinding, flotation, leaching and filtration stages, of the lithium sulfate present in potassium Carnallite (KCl*MgCl2*6H2O) stockpiles with high contents of lithium sulfate (Li2SO4*H2O) and sodium chloride (NaCl). The greatest advantage of the invention's process is that it uses salts and brines which are not currently being processed today and which have already been extracted far potassium production.