Patent SORBENT FOR LITHIUM EXTRACTION

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Patent SORBENT FOR LITHIUM EXTRACTION ( patent-sorbent-for-lithium-extraction )

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US 8,753,594B1 56 sizecanbegreater,forexample,between200and500um,or greater,andtheresultinglargerparticlescanthenbereduced insizebygrindingorbyotherprocedure.Theuseofparticles resultingfromthegrindingoflargerparticles,however,canin certaininstancesresultinmaterialshavingareducedcapacity andameasurablegibsitecontent. 20%byvolumeoftheplasticmaterial.Inalternateembodi ments,thematrixincludesatleastabout85%byvolumeof theLAIanduptoabout15%byvolumeoftheplasticmate rial.Alternatively,thematrixcanincludeatleastabout90% byvolumeoftheLAIanduptoabout10%byvolumeofthe plasticmaterial.Incertainembodiments,thematrixincludes betweenabout85-95%byvolumeoftheLAI,andbetween Thepolymerorplasticbindermaterialthatmakesupthe about5-15%byvolumeoftheplasticmaterial.Inalternate embodiments,thematrixincludesbetweenabout88-94%by volumeoftheLAI,andbetweenabout6-12%byvolumeof10 theplasticmaterial.Inanexemplaryembodiment,theLAI matrixincludesabout90%byvolumeLAIandabout10%by Volumeofthepolymerorplasticmaterial. matrixcanbeselectedfromanysuitablethermoplasticor thermosetpolymermaterial.Representativethermoplastic resinscanincludepolyethylene(PE)(includingultrahigh molecularweightpolyethylene(UHMWE),highdensity polyethylene(HDPE),andlinearlowdensitypolyethylene (LLDPE)),aswellasvariousethyleneco-polymerssuchas ethylenevinylacetate,ethylenevinylalcohol,ethylenevinyl chloride,ethyleneco-acrylate,orsimilarmaterials,polypro pylene(PP)anditscopolymers,polymethylpentene, polystryene,polyvinylalcohol(PVA),polyacrylicacid (PAA),polyacrylamide(PAM),acrylicandmethacrylicpoly mers,polycarbonate,polyacrylonitrile(PAN),polyvinylidin edifluoride(PVDF)homoorco-polymers,polytetrafluoroet hylene(PTFE),andrelatedfluoropolymers,polyurethanes, andpolysiloxanes.Representativethermosetresinscan includeepoxyresins,phenolicresins,vinylesterresins,one ortwocomponentmethacrylicresins,melaminebasedresins, cros-linkedpolysiloxanes,orotherplasticorpolymeric materialsthatcanfunctionasSuitablematrixmaterials.Inone embodiment,thelithiumaluminatematrixispreparedfroma polymerthatfacilitatesgranulation.Inanotherembodiment, thematrixpolymerprecursoriswaterbased,suchasawater solubleresin,anaqueousdispersion,oranemulsion.Incer tainembodiments,theplasticandpolymericmaterialsare suitableforoperationattemperaturesinexcessofabout90° C.Alternatively,thematerialsaresuitableforoperationat temperaturesinexcessofabout100°C.Inyetotherembodi ments,thematerialsareSuitableforoperationattemperatures inexcessofabout110°C.Thepolymerorplasticmaterialcan beaddedtotheLAImaterialasasolidpowderorpeletform andmixedtogether,oritcanbeaddedasaloworhigh viscosityfluid.Preferably,theLAIandthepolymerorplastic materialarethoroughlymixedtogether. TheLAIcanbepreparedbyknownmeans.Suchasis describedinU.S.Pat.No.6,280,693toBauman,etal.Gen 15 eraly,incertainembodiments,theLAIcanbepreparedby contactingaluminapelets,lithiumhydroxide,andwater,and allowingthelithiumhydroxidetoinfusethealumina.Incer tainembodiments,thelithiumhydroxidecanbereplacedwith lithiumsalts,suchaslithiumchlorideorotherlikelithium salts,andcombinationsthereof.Suitablesourcesofthealu minacanincludegibsite,aluminahydrate,bayerite,nord standite,bauxite,amorphousaluminumtrihydroxideand activatedalumina.Theinfusioncanbeaslowprocessthatis typicalycompletedinabout2-48hours,althoughitisunder25 stoodthattheprocesscanproceedatdiferentrates,depend ingupontheexactconditions,suchastemperature,usedfor theinfusionproces.Infusionistypicalycariedatornear roomtemperature,butcanalsobecariedoutatelevated temperaturesuptoabout125°C.(atpressuresoflesthan30 about5atm).Followinginfusionofthelithiumhydroxide intothealumina,thesolutioncanthenbeneutralizedby addinghydrochloricacidorotherlikeacid,toachieveapHof betweenabout5and7.WhentheacidusedisHCl,the acidificationofthesolutionproducesLiC1/2Al(OH).Itisthe35 intentiontofracturetheinfusedmaterial,therebygenerating afineparticulatemater,ratherthananintegralmass.In certainembodiments,thefineparticulatematterhasadiam eteroflesthanabout80um,alternativelylesthanabout50 um,alternativelylesthanabout25um,alternativelylesthan40 about10Lum.Incertainembodiments,thematerialhasa Incertainembodiments,thepolymerisanemulsifiedwater bimodalsizedistributionwhereinthematerialhasafirstpeak distributionofabout50umandasecondpeakdistributionof about10um.Incertainembodiments,theparticulatematerial hasadiameterofbetweenabout0.1and8um,alternatively45 betweenabout0.5and5um.Incertainembodiments,atleast 50%oftheparticulatematterhasadiameteroflessthanabout Incertainembodiments,thepolymer/plasticmaterialand 2um,alternativelyatleastabout75%oftheparticulatematter hasadiameteroflesthanabout2um,alternativelyatleast about90%oftheparticulatematterhasadiameteroflessthan50 about2um.Incertainembodiments,thelithiumhydroxideis addedtothealuminainamolarratioofbetweenabout1:1and 1:5,preferablybetweenabout1:2and1:4.ThefinalizedLAI matrixpreferablyhasastoichiometriccompositionofLiCl: Al(OH)ofbetweenabout1:2and1:4,preferablybetween55 about0.75:2and1:2.Incertainembodiments,theLAIcanbe usedasprepared.Inalternateembodiments,theLAIcanbe usedasamilledmaterialusingknowntechniquestomilthe LAI.Inyetotherembodiments,theLAIcanalsobeprepared bytreatingamilledaluminahydrateandwithlithiumhydrox60 ide,followedbyneutralizationwithacid.Generaly,incon trasttosimilarpriorartcompositionswhichutilizeintegral polycrystalinecompositions,thepresentinventionprefer Inoneexemplaryembodiment,anLAImatrixisprepared ablyutilizesparticulateLAImaterial,whereintheparticulate mattercangeneralyhaveanyshapeorsize,andmayhavea65 diameteroflesthanabout100um,alternativelyadiameter oflesthanabout50lum.Incertainembodiments,theparticle fromamixturethatincludestheLAIpowderandapowdered polymer,whichcanbecombinedinamixingveseland thoroughlymixed.TheresultingLAIpowderandpowdered polymermixturecanthenbesubjectedtoelevatedtempera insolublepolymer.Incertainembodiments,thewater insolublepolymerisafluoropolymer.Incertainembodi ments,thewaterinsolublepolymerisanacrylicinterpolymer. Incertainembodiments,thepolymercanbeacrosslinked polymer. theLAImaterialcanbemixedtogetherandsinteredat elevatedtemperaturetoformtheLAImatrix.Incertain embodiments,pressurecanbeappliedtothemixturebefore, during,orafterthesinteringproces.Incertainembodiments, upto10,000psicanbeappliedtothemixture,withorwithout concurrentheatingthereof.Incertainembodiments,pressure ofatleast2500psiisaplied.Inalternateembodiments, increasinglygreaterpressuresareappliedtothemixture.The resultingsinteredproductistypicalyasolid,whichcanthen bebrokenintosmallerpieces,preferablytoformapluralityof particulates,foruse.Optionaly,theSolidsinteredproducts canbegroundtoadesiredparticulatediameterorsize.In certainembodiments,thegroundLAImatrixcanbesepa rated,usingforexamplesieves,toprovidemultiplesizesor rangesofdiametersoftheLAImatrixparticles.

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