Lithium refining with crystallization systems

Condorchem Enviro Solutions offers comprhensive solutions for the concentration and refining of lithium. Our crystallization systems are engineered to handle the unique impurity profiles of various lithium sources:

• Traditional brine evaporation ponds
• Hard rock mines
• Modern direct lithium extraction (DLE) processes

We provide the necessary technology to transform dilute lithium chloride solutions obtained in DLE processes into high-purity lithium carbonate and lithium hydroxide.

Our crystallization plants can be deployed as a complete turnkey system or integrated individually into an existing process.

DESALT MVR FCVacuum crystallizers by mechanical vapour recompression and forced circulationDESALT VRThermal vacuum crystallizersDESALT LT VRHeat pump vacuum crystallizersDESALT MFEThermal vacuum crystallizers by forced circulationDESALT LT DRYHeat pump vacuum crystallizers

Crystallizers are the core technology for producing valuable, battery-grade lithium products. A well-engineered crystallization plant controls the formation and growth of crystals to effectively separate impurities and achieve the required purity.

Condorchem Enviro Solutions designs and supplies robust crystallization systems tailored to our customers needs. Our crystallizers enable clients to:

• Maximize the recovery of high-purity, battery-grade lithium hydroxide and lithium carbonate.
• Effectively remove contaminants through precise process control.
• Improve overall process efficiency to reduce operational costs and increase revenue.

The following forms of lithium can be obtained after the crystallization process:

• LiOH·H₂O is typically obtained via forced-circulation (FC) evaporative crystallizers that keep solids suspended and resist scaling—ideal for steady, clean growth.
• Li₂CO₃: can be produced via draft tube baffle (DTB) crystallizers to produce larger, more uniform crystals with high purity, then washed and centrifuged for final spec. Bench and pilot work define washing and breakage limits.
• Precise carbonation and refining enable >99.9% Li₂CO₃ when required.

We offer bench, pilot and full-scale design so your commercial system is de-risked on crystal yield, morphology and centrifuge performance before you build.

Mechanical Vapor Recompression (MVR) crystallizers deliver superior energy efficiency and operational reliability. MVR crystallization systems use electricity to power a compressor that recycles heat, making them a cost-effective choice where affordable steam is unavailable.

Key features of our MVR crystallizers include:

• Systems are equipped with smart controls for self-cleaning, automated startup and shutdown, and capacity control, ensuring high uptime and ease of operation.
• Built with high-quality, corrosion-resistant materials and Tier 1 components, our MVR crystallizers are designed for durability and reliability.
• Our crystallization systems can integrate a complete package for solids production, including decanter centrifuges and slurry management systems, to deliver a final, dewatered product.
• MVR crystallizers are instrumental in achieving zero liquid discharge (ZLD) for wastewater streams, ensuring environmental compliance and promoting sustainable
  operations.

DESALT MVR FCVacuum crystallizers by mechanical vapour recompression and forced circulationDESALT VRThermal vacuum crystallizersDESALT LT VRHeat pump vacuum crystallizersDESALT MFEThermal vacuum crystallizers by forced circulationDESALT LT DRYHeat pump vacuum crystallizers

1. Direct Lithium Extraction (DLE) and Pre-treatment

The process begins with raw lithium brine, which is first sent to a Direct Lithium Extraction (DLE) unit. The diagram notes that this DLE process is typically handled by other specialized companies.

This stage uses inputs like HCl and wash water to selectively extract lithium, producing an initial LiCl (lithium chloride) solution and a waste brine stream. Any waste wash water from this stage can be treated and recovered using Reverse Osmosis (XtremeRO).

The LiCl solution then undergoes Precipitation & Pre-treatment to remove impurities. This involves:

• Optional Chemical Precipitation (BrineRefine): This step targets and removes scaling ions that could foul downstream equipment.
• Ultrafiltration (XtremeUF): The solution is then filtered to remove any suspended solids, resulting in a clean, "Processed LiCl Solution" ready for the next stage.

2. Concentrating the LiCl Solution

After pre-treatment, the processed LiCl solution is concentrated to increase the lithium content. The primary method shown is Reverse Osmosis (XtremeRO/IARO), which efficiently removes water.

As an alternative or supplementary step, an Evaporator (SaltMaker MVR) can be used for further concentration. The output is a highly "Concentrated LiCl Solution".

3. Conversion to Final Battery-Grade Product

From the concentrated LiCl solution, the process can split into three distinct paths to produce either lithium hydroxide or lithium carbonate.

Path A: LiOH Electrochemical process

This is a direct process to produce lithium hydroxide.

1. Electrochemical Conversion: The concentrated LiCl solution undergoes electrochemical conversion to LiOH, a process that also involves High TDS Ion Exchange. This step produces hydrogen (H₂) and chlorine (Cl₂) as byproducts.
2. Crystallization: The resulting LiOH solution is sent to a Thermal 2-Step Crystallization process using an MVR system (Crystallizer + Centrifuge) to produce solid crystals.
3. The output is Battery-Grade Lithium Hydroxide Monohydrate (LiOH.H₂O).

Path B: LiOH Lime process

This process involves more traditional chemical precipitation methods.

1. Initial Conversion to Carbonate: Sodium carbonate (Na₂CO₃) is added to the concentrated LiCl solution in a chemical precipitation step to produce solid lithium carbonate (Li₂CO₃).
2. Conversion to Hydroxide: Lime slurry is then added to the Li₂CO₃ in a second chemical precipitation step, which converts it to LiOH and precipitates calcium carbonate (CaCO₃) solids.
3. Purification and Crystallization: The LiOH solution is further purified with High TDS Ion Exchange, before being crystallized in the MVR Crystallization system.
4. This process also produces Battery-Grade Lithium Hydroxide Monohydrate (LiOH.H₂O).

Path C: Li₂CO₃ Process

This is the dedicated route for producing lithium carbonate.

1. Conversion and Precipitation: The concentrated solution is converted to Li₂CO₃, first passing through a High TDS Ion Exchange unit and then into a Chemical Precipitation reactor, where sodium carbonate (Na₂CO₃) is added.
2. After this step, it is possible to extract technical grade Li₂CO₃ solids as an intermediate product.
3. The main stream continues to an upgrading process to achieve higher purity.
4. The final output is Battery-Grade Lithium Carbonate (Li₂CO₃).

Condorchem Enviro Solutions team has an extensive experience in the design of lithium crystallization systems that meet the unique demands of every lithium source and achieve the purity targets requested by the client.

• Our process begins with thorough analysis and testing that will allow us to gather the data needed for a successful commercial plant design.
• Our systems can be delivered as pre-assembled, factory-tested modules, reducing on-site construction time and cost, minimizing risks and allowing for rapid, scalable deployment.
• Our lithium refining systems are designed to minimize environmental impact, focusing on water recovery with membrane filtration and Zero Liquid Discharge with efficient crystallizers.

Whether you need a complete brine-to-battery chemical plant or a single high-performance unit operation, Condorchem Enviro Solutions delivers the technology and expertise to accelerate your project from concept to production.

Contact our experts today to discuss your lithium refining needs and discover how our intelligent solutions can maximize your project's performance and profitability.