Abstract
Direct Lithium Extraction (DLE) technologies offer a transformative approach to lithium recovery from different types of brines, bypassing traditional evaporation methods. However, the selective nature of the DLE processes demands rigorous process risk management and monitoring of impurity profiles in the aqueous streams. Impurities such as magnesium, calcium, bromine, sulfate, organics, transition metals, and magnetic metallics, can compromise lithium purity and therefore affect battery-grade specifications. Other impurities can also affect downstream processes and damage downstream equipment. The main difference between different Li salt grades is the minimum lithium content and the maximum tolerable impurities. Impurities influence production processes, cathode quality and performance, and, most importantly, safety. Most lithium battery faults originate from the presence of impurities. This, coupled with production processes and safety aspects, puts pressure on material purity, with a focus on trace elements' characteristics and their content. The present study emphasizes the importance of brine characterization and screening for different types of brine, pretreatment protocols, and real-time monitoring to identify impurity profiles and their dynamic behavior during extraction. Brines from different sources (salar, petro brines, geothermal, etc.) are considered here and the risk of impurity contamination is quantified using a risk assessment tool. A robust impurity risk assessment and impurity management protocol not only ensures compliance with battery-grade standards but also mitigates several process risks, enhances process sustainability, and economic viability.