Processing of lithium containing material including HCl sparge

1. A process for the treatment of a lithium containing material, the process comprising the steps of:

(i) Preparing a process solution from the lithium containing material, wherein the lithium containing material is alpha-spodumene and the alpha-spodumene is calcinated to produce beta-spodumene, and

wherein the process solution is prepared from a pregnant leach solution and the pregnant leach solution is formed by passing the beta-spodumene to a leach step comprising a first leach stage and a second leach stage in which the material is leached with hydrochloric acid to form the pregnant leach solution, and passing the pregnant leach solution to a thickening circuit comprising a first thickening stage aligned subsequent with the first leach stage and a second thickening stage aligned subsequent with the second leach stage and subsequently pyrohydrolysing an overflow from the thickening circuit, thereby converting any chlorides of aluminum and iron into insoluble oxides, wherein an underflow from the first thickening stage aligned subsequent with the first leach stage is passed to the second leach stage, and wherein an underflow from the second thickening stage aligned subsequent with the second leach stage is passed to waste;

(ii) Passing the process solution from step (i) without a concentration step for removal of sodium and potassium impurities to a series of impurity removal steps, including a first step for removal of multivalent cations of at least one of a) raising pH of the process solution and b) addition of either sodium carbonate or lithium carbonate, and one or more subsequent steps for removal of monovalent cations, one of which is an HCl sparging step for removal of sodium, thereby providing a purified lithium chloride solution and recovered HCl;

(iii) Passing the purified lithium chloride solution of step (ii) to an ion exchange step that removes remaining calcium and magnesium therefrom; and

(iv) Passing the purified lithium chloride solution of step (iii) to an electrolysis step, thereby producing a lithium hydroxide solution, chlorine, and hydrogen, the chlorine and hydrogen being combined to provide additional recovered HCl,

wherein the process solution is not subjected to either the concentration step or a fractional crystallization step prior to any of the series of impurity removal steps of step (ii) and the ion exchange step of step (iii) and the electrolysis step of step (iv),

wherein the HCl sparging step of step (ii) comprises the sparging of HCl gas into the process solution whereby the HCl concentration thereof increases to a point at which sodium present precipitates and wherein the HCl concentration of the process solution is increased to: (i) at least about 30% w/w; or (ii) at least about 36% w/w; and

wherein HCl acid is recovered from the HCl sparging step of step (ii) and recycled to step (i).

2. The process according to claim 1 , wherein the lithium hydroxide solution produced in step (iv) is carbonated by passing compressed carbon dioxide through the solution, thereby producing a lithium carbonate precipitate.

3. The process according to claim 1 , wherein the HCl sparging step is followed by a filtration step to remove any precipitated sodium and potassium.

4. The process according to claim 1 , wherein the HCl sparging step is followed by a filtration step to remove any precipitated sodium and potassium, and the HCl sparging and filtration steps are followed by an HCl recovery step.

5. The process according to claim 1 , wherein the lithium hydroxide solution produced in step (iv) is thickened by evaporation of water to provide lithium hydroxide monohydrate crystals.

6. The process according to claim 1 , wherein a first portion of the lithium hydroxide solution produced in step (iv) is thickened by evaporation/crystallisation producing lithium hydroxide monohydrate crystals, and a second portion thereof is carbonated by passing compressed carbon dioxide through the solution, thereby producing a lithium carbonate precipitate.

7. The process according to claim 1 , wherein the impurity removal steps of step (ii) further include one or more of hydropyrolysis of Al and Fe chlorides, pH increase to precipitate hydroxides of Al, Fe, Mg and Mn, and lithium carbonate precipitation for removal of Ca.

8. The process according to claim 7 , wherein the ion exchange step removes substantially all multivalent cations in the pregnant leach solution to a level of less than about 10 ppm.

9. The process according to claim 1 , wherein the beta-spodumene is milled prior to the first step to a size of:

(i) less than about 300 μm; or

(ii) a P 80 of about 75 μm.

10. The process according to claim 1 , wherein a leach step that produces the pregnant leach solution is conducted at elevated temperature.

11. The process according to claim 1 , wherein the pregnant leach solution is formed by passing a lithium containing material to a leach step in which the material is leached with hydrochloric acid at 20% HCl w/w.

12. The process according to claim 1 , wherein the leach step that produces the pregnant leach solution is conducted at an elevated temperature that is about the boiling point of hydrochloric acid solution used in the leach step, and the leach step is conducted at atmospheric pressure.

13. The process according to claim 1 , wherein the leach step that produces the pregnant leach solution is conducted in a chlorination kiln at about 108° C. over a residence time of:

(i) about 6 to 10 hours; or

(ii) about 8 hours.

14. The process according to claim 1 , wherein the overflow from the thickening circuit is first directed to a belt filter and the pregnant leach solution is then directed to a distillation step in which excess HCl is recovered and then passed to the pyrohydrolysing.

15. The process according to claim 14 , wherein the pyrohydrolysing is performed at about 300° C.

16. The process according to claim 15 , wherein recovered HCl from the pyrohydrolysing is sent to a HCl tank.