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Abstract

Methods are provided for processing a lithium-containing material (e.g., a mineral like spodumene) whereby a lithium sulfate solution derived from the material is reacted with a primary reagent (e.g., Na₂CO₃ or NaOH) to produce a mixed solution of primary lithium product (e.g., Li₂CO₃ or LiOH) and Na₂SO₄. In addition to primary lithium product, a separated Na₂SO₄ solution is produced and converted to a byproduct (e.g., CaSO₄, NaNO₃, NaOH, H₂SO₄) by reaction with a salt chemical (e.g., Ca(NO₃)₂) or alkali chemical (e.g., Ca(OH)₂), or by electrolysis or electrodialysis. Byproducts are re-used to reduce reagent inputs. Residual lithium in an output solution is reacted with a secondary reagent (e.g., CO₂ from flue gas, or H₃PO₄) to produce secondary lithium products (e.g., Li₂CO₃ or Li₃PO₄), which may be re-used to reduce reagent inputs and increase lithium recovery.

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