Lithium extraction with porous ion exchange beads

1. A method of making porous ion exchange beads, comprising:

(a) combining and mixing i) ion exchange particles that reversibly exchange lithium with hydrogen, ii) a matrix material, and iii) a filler material to make a mixture;

(b) forming the mixture into beads;

(c) optionally heating the beads; and

(d) removing the filler material to make porous ion exchange beads.

2. The method of claim 1 , wherein the combining and mixing at step (a) comprises mixing the ion exchange particles, matrix material, filler material, or combinations thereof as dry powders.

3. The method of claim 1 , wherein the combining and mixing at step (a) comprises using one or more solvents, wherein the mixture is a slurry.

4. The method of claim 1 , wherein the heating at step (c) melts or sinters the matrix material.

5. The method of claim 1 , wherein the removing at step (d) comprises dissolving the filler material using water, an aqueous solution, an acid, a brine, an alcohol, acetone, or combinations thereof.

6. The method of claim 1 , wherein the removing at step (d) comprises heating the beads so as to remove the filler material through sublimation or evaporation, or to decompose the filler material to decomposition products.

7. The method of claim 1 , wherein the ion exchange particles comprise coated ion exchange particles, uncoated ion exchange particles, or combinations thereof.

8. The method of claim 7 , wherein the coated ion exchange particles comprise an ion exchange material and a coating material.

9. The method of claim 8 , wherein the coating material of the coated ion exchange particles is selected from the group consisting of: a carbide, a nitride, an oxide, a phosphate, a fluoride, a polymer, carbon, a carbonaceous material, and a combination thereof.

10. The method of claim 9 , wherein the coating material of the coated ion exchange particles is selected from the group consisting of: TiO 2 , ZrO 2 , MoO 2 , SnO 2 , Nb 2 O 5 , Ta 2 O 5 , SiO 2 , Li 2 TiO 3 , Li 2 ZrO 3 , Li 2 SiO 3 , Li 2 MnO 3 , Li 2 MoO 3 , LiNbO 3 , LiTaO 3 , AlPO 4 , LaPO 4 , ZrP 2 O 7 , MoP 2 O 7 , Mo 2 P 3 O 12 , BaSO 4 , AlF 3 , SiC, TiC, ZrC, Si 3 N 4 , ZrN, BN, carbon, graphitic carbon, amorphous carbon, hard carbon, diamond-like carbon, solid solutions thereof, and a combination thereof.

11. The method of claim 9 , wherein the coating material of the coated ion exchange particles is selected from the group consisting of: polyethylene, low density polyethylene, high density polyethylene, polypropylene, polyphenylene sulfide, polyester, polytetrafluoroethylene, types of polyamide, polyether ether ketone, polysulfone, polyvinylidene difluoride, poly (4-vinyl pyridine-co-styrene), polystyrene, polybutadiene, acrylonitrile butadiene styrene, polyvinyl chloride, polyvinylidene dichloride, ethylene tetrafluoroethylene polymer, poly(chlorotrifluoroethylene), ethylene chlorotrifluoro ethylene, polyvinyl fluoride, fluorinated ethylene-propylene, perfluorinated elastomer, chlorotrifluoroethylenevinylidene fluoride, perfluoropolyether, perfluorosulfonic acid, polyethylene oxide, polyethylene glycol, sodium polyacrylate, polyethylene-block-poly(ethylene glycol), polyacrylonitrile, polychloroprene (neoprene), polyvinyl butyral, expanded polystyrene, polydivinylbenzene, tetrafluoroethylene-perfluoro-3,6-dioxa-4-methyl-7-octenesulfonic acid copolymer, copolymers thereof, and a combination thereof.

12. The method of claim 8 , wherein the coated ion exchange particles and the uncoated ion exchange particles independently comprise ion exchange material that is selected from the group consisting of: an oxide, a phosphate, an oxyfluoride, a fluorophosphate, and a combination thereof.

13. The method of claim 8 , wherein the coated ion exchange particles and the uncoated ion exchange particles independently comprise ion exchange material that is selected from the group consisting of: Li 4 Mn 5 O 12 , Li 4 Ti 5 O 12 , Li 2 TiO 3 , Li 2 MnO 3 , Li 2 SnO 3 , LiMn 2 O 4 , Li 1.6 Mn 1.6 O 4 , LiAlO 2 , LiCuO 2 , LiTiO 2 , Li 4 TiO 4 , Li 7 Ti 11 O 24 , Li 3 VO 4 , Li 2 Si 3 O 7 , LiFePO 4 , LiMnPO 4 , Li 2 CuP 2 O 7 , Al(OH) 3 , LiCl.xAl(OH) 3 .yH 2 O, SnO 2 .xSb 2 O 5 .yH 2 O, TiO 2 .xSb 2 O 5 .yH 2 O, solid solutions thereof, and a combination thereof; wherein x is from 0.1-10; and y is from 0.1-10.

14. The method of claim 1 , wherein the matrix material is selected from the group consisting of: a polymer, an oxide, a phosphate, and a combination thereof.

15. The method of claim 14 , wherein the matrix material is selected from the group consisting of: polyvinyl fluoride, polyvinylidene difluoride, polyvinyl chloride, polyvinylidene dichloride, polyethylene, polypropylene, polyphenylene sulfide, polytetrafluoroethylene, sulfonated polytetrafluoroethylene, polystyrene, polydivinylbenzene, polybutadiene, poly-ethylene-tetrafluoroethyelene, polyacrylonitrile, sulfonated polymer, carboxylated polymer, tetrafluoroethylene-perfluoro-3,6-dioxa-4-methyl-7-octenesulfonic acid copolymer, copolymers thereof, and a combination thereof.

16. The method of claim 1 , wherein the filler material is selected from the group consisting of: a salt, a chloride salt, sodium chloride, a sulfate salt, a carbonate salt, a nitrate salt, an alkali metal salt, an alkali earth metal salt, an organic material, a polymer, an aqueous liquid, an organic liquid, a liquid mixture, and a combination thereof.

17. The method of claim 1 , wherein the filler material is removed at step (d) by sublimation or evaporation by subjecting the beads to heat, vacuum, air, or combinations thereof.

18. The method of claim 1 , wherein the porous ion exchange beads have an average diameter of greater than about 100 μm and less than about 1000 μm.