A powder with particulates of a lithium ion-conducting material has a conductivity of at least 10.sup.−5 S/cm. The powder has an inorganic carbon content (Total Inorganic Carbon Content (TIC)) of less than 0.4 wt % and/or an organic carbon content (Total Organic Carbon Content (TOC)) of less than 0.1 wt %. The particulates have a d50 particle size in a range from 0.05 μm to 10 μm. The particulates have a particle size distribution log (d90/d10) of less than 4.

A powder with particulates of a lithium ion-conducting material has a conductivity of at least 10.sup.−5 S/cm. The powder has an inorganic carbon content (Total Inorganic Carbon Content (TIC)) of less than 0.4 wt % and/or an organic carbon content (Total Organic Carbon Content (TOC)) of less than 0.1 wt %. The particulates have a d50 particle size in a range from 0.05 μm to 10 μm. The particulates have a particle size distribution log (d90/d10) of less than 4.

Provided herein are processes for recovering lithium ions from a brine source. The process can comprises increasing the pH of a brine source comprising lithium ions to at least about 5.5; contacting the pH-elevated brine source with a bed of protonated ion exchange media to produce a lithiated ion exchange media and a lithium-depleted brine stream; contacting the lithiated ion exchange media with an acidic aqueous wash liquid; and contacting the washed lithiated ion exchange media with an elution liquid comprising an acid. Also provided herein is a process for increasing the pH of brine comprising obtaining brine from a brine source comprising lithium ions; adding the brine to a continuously stirred tank reactor without preprocessing the brine to remove solid matter; adding a strong base to the continuously stirred tank reactor; contacting the brine with the base. Further provided herein are processes for creating a lithiated ion exchange media, which can comprise contacting a pH-elevated brine source with a bed of protonated ion exchange media; and producing a lithiated ion exchange media and a spent brine, wherein the bed of protonated ion exchange media comprises a metal oxide absorbent and a polymeric binder.

Provided herein are processes for recovering lithium ions from a brine source. The process can comprises increasing the pH of a brine source comprising lithium ions to at least about 5.5; contacting the pH-elevated brine source with a bed of protonated ion exchange media to produce a lithiated ion exchange media and a lithium-depleted brine stream; contacting the lithiated ion exchange media with an acidic aqueous wash liquid; and contacting the washed lithiated ion exchange media with an elution liquid comprising an acid. Also provided herein is a process for increasing the pH of brine comprising obtaining brine from a brine source comprising lithium ions; adding the brine to a continuously stirred tank reactor without preprocessing the brine to remove solid matter; adding a strong base to the continuously stirred tank reactor; contacting the brine with the base. Further provided herein are processes for creating a lithiated ion exchange media, which can comprise contacting a pH-elevated brine source with a bed of protonated ion exchange media; and producing a lithiated ion exchange media and a spent brine, wherein the bed of protonated ion exchange media comprises a metal oxide absorbent and a polymeric binder.

A process for preparing a metal hydroxide comprising (i) at least one metal chosen from nickel and cobalt and optionally (ii) at least one metal chosen from manganese, lithium and aluminum. The process comprises: reacting a metal sulfate comprising (i) at least one metal chosen from nickel and cobalt and optionally (iii) at least one metal chosen from manganese and aluminum with sodium hydroxide and optionally a chelating agent in order to obtain a solid comprising the metal hydroxide and a liquid comprising sodium sulfate; separating the liquid and the solid from one another to obtain the metal hydroxide; submitting the liquid comprising sodium sulfate to an electromembrane process for converting the sodium sulfate into sodium hydroxide; and reusing the sodium hydroxide obtained by the electromembrane process for reacting with the metal sulfate.

A process for preparing a metal hydroxide comprising (i) at least one metal chosen from nickel and cobalt and optionally (ii) at least one metal chosen from manganese, lithium and aluminum. The process comprises: reacting a metal sulfate comprising (i) at least one metal chosen from nickel and cobalt and optionally (iii) at least one metal chosen from manganese and aluminum with sodium hydroxide and optionally a chelating agent in order to obtain a solid comprising the metal hydroxide and a liquid comprising sodium sulfate; separating the liquid and the solid from one another to obtain the metal hydroxide; submitting the liquid comprising sodium sulfate to an electromembrane process for converting the sodium sulfate into sodium hydroxide; and reusing the sodium hydroxide obtained by the electromembrane process for reacting with the metal sulfate.

A system and process for direct lithium extraction from geothermal brines, and more particular to the sequential combination of a binary cycle geothermal plant, a direct lithium extraction circuit, a lithium chloride concentration and purification circuit, and a lithium battery chemical processing circuit, for the production of battery-quality lithium hydroxide monohydrate, lithium carbonate or both from geothermal brines. The processing circuits are powered by the electricity and heat produced by the binary cycle geothermal plant without the use of carbon-based fuels. Non-condensable gases that may come out of solution from the geothermal brine are not emitted into the atmosphere.

A system and process for direct lithium extraction from geothermal brines, and more particular to the sequential combination of a binary cycle geothermal plant, a direct lithium extraction circuit, a lithium chloride concentration and purification circuit, and a lithium battery chemical processing circuit, for the production of battery-quality lithium hydroxide monohydrate, lithium carbonate or both from geothermal brines. The processing circuits are powered by the electricity and heat produced by the binary cycle geothermal plant without the use of carbon-based fuels. Non-condensable gases that may come out of solution from the geothermal brine are not emitted into the atmosphere.

In a method for regenerating a lithium precursor, a cathode active material mixture that includes an active material powder including lithium composite oxide particles and dust particles is prepared. The dust particles are separated from the cathode active material mixture using a classifier to collect the active material powder. The active material powder is reduced to form a preliminary precursor mixture. A lithium precursor is recovered from the preliminary precursor mixture. The lithium precursor can be obtained with high purity and high yield.

A method of manufacturing a secondary battery cathode material includes preparing Li.sub.2O powder by separating CO.sub.2 from Li.sub.2CO.sub.3 powder, forming a mixed powder by mixing the Li.sub.2O powder with nickel-cobalt-manganese (NCM) precursor powder, and firing the mixed powder using a rotary kiln.