Cost-Saving Strategy: How to Reduce Cost in Lithium Ore Processing?

Project-site-of-200wtpa-lithium-processing-plant

Optimizing the lithium ore extraction and refining process not only enhances corporate profits, but also strengthens market competitiveness. In this paper, we will discuss in depth how to reduce the cost of lithium ore processing from the aspects of beneficiation, energy consumption, reagent use, process optimization, extraction methods and logistics.

Beneficiation is the first step in lithium ore processing, improve beneficiation efficiency can significantly reduce the cost of subsequent grinding and flotation.

1. Sensor-based Ore Sorting

Advanced sensor-based sorting technology can reduce energy consumption by removing waste rock after crushing and reducing the amount of low-grade ore entering the grinding process.

2. Froth Flotation Optimization

By optimizing the ratio of flotation reagents, the recovery rate of lithium pyroxene or lithium mica can be increased, the flotation waste can be reduced, and the concentrate grade can be increased.

3. Dense Media Separation (DMS)

For high-grade lithium ores, DMS can reduce the need for grinding and flotation, thus reducing the cost of chemicals and energy consumption.

The high-temperature calcination, dissolution and evaporation stages of lithium ore processing consume a lot of energy, and optimizing energy use is the key to reducing costs.

1. Adoption of renewable energy

Adopting solar, wind or geothermal energy at the processing plant reduces electricity costs and complies with environmental regulations.

2. Optimize the roasting process

By adding sodium carbonate or limestone, the roasting temperature of lithium faience can be lowered (900°C instead of 1050°C) to reduce fuel consumption.

Investigating the use of microwave heating technology to improve heating efficiency.

3. Highly efficient heat recovery

Adopting waste heat recovery system to utilize the heat discharged from the roaster to preheat the ore or produce steam can save a lot of energy.

Choose energy-saving rotary kiln or fluidized bed roaster to improve fuel utilization.

The lithium extraction process uses a large number of acid and alkali reagents, such as sulfuric acid, sodium hydroxide (NaOH) and lime. Optimizing the use and recycling of reagents can reduce operating costs.

1. Sulfuric acid and sodium hydroxide recycling

Recycling sulfuric acid through an acid recycling system reduces the cost of purchasing new acid and lowers waste liquid disposal costs.

2. Optimization of Alkaline Precipitation Process

Precise control of NaOH and lime addition reduces waste and improves precipitation efficiency.

3. Adoption of alternative leaching processes

Investigate the use of hydrochloric acid leaching (HCl Leaching) or direct lithium extraction (DLE) methods to reduce reliance on high-cost sulfuric acid.

1. Automated control systems

Monitor parameters such as temperature, pH, reagent dosage, etc. through Artificial Intelligence (AI) and Internet of Things (IoT) to accurately control the production process and reduce excessive consumption.

2. High Efficiency Filtration and Membrane Separation

The use of high-efficiency filters and nanofiltration/reverse osmosis membranes reduces solid impurities and improves lithium recovery while reducing the use of chemical reagents.

3. Recycled Water Utilization

Adoption of closed-loop water treatment system reduces new water consumption and wastewater discharge, and lowers environmental management costs.

In addition to the traditional sulfuric acid roasting method, companies can also consider adopting more cost-effective extraction techniques.

1. Direct Lithium Extraction (DLE)

Lithium is extracted from lithium brine or ore using selective adsorption, ion exchange or solvent extraction techniques, avoiding the long waiting time and high water consumption associated with evaporation cells.

It is suitable for low-grade lithium ore or brine resources to improve resource utilization.

2. Bioleaching

Dissolve lithium ore through microbial leaching technology, reducing the use of chemical reagents.

Applicable to low grade ores, improve recovery and reduce pollution.

3. Electrodialysis and Membrane Separation

Selective separation of lithium using membrane technology reduces the use of precipitants and improves purity.

Suitable for brines with high Mg/Li ratios (e.g. Qinghai, Bolivian salt lakes).

1. Build processing plants close to mines

Building primary processing plants near mines can reduce raw ore transportation costs and improve economic efficiency.

2. Modularized processing plants

Processing plants with modular design can reduce initial investment and expand capacity according to market demand.

3. Optimized Supply Chain Management

Reduce import costs by sourcing reagents and equipment locally.

Adopt intelligent inventory management system to reduce capital utilization caused by excessive stockpiling.

Reducing lithium processing costs requires optimization from multiple perspectives, including improving beneficiation efficiency, reducing energy consumption, reducing reagent use, optimizing processes, and adopting new technologies. For different types of lithium resources:

1. Hard rock lithium ores (e.g. lithium pyroxene): priority should be given to optimizing roasting temperature, acid recovery and automated control.

2. Lithium brine extraction (e.g. salt lakes): Direct lithium extraction (DLE) and high efficiency evaporation technologies can be used to improve recovery and reduce water consumption.

By combining multiple technologies and management tools, lithium mining companies can effectively reduce production costs, improve market competitiveness, and promote sustainable development.

What are some of the challenges your organization has encountered in lithium processing? Feel free to leave a comment to share!