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From Lithium Ores to Battery Cells: Ore-to-Precursor Transformations, Extraction of Li2SO4 from β-Spodumene, and Electrode Balancing

Title:

From Lithium Ores to Battery Cells: Ore-to-Precursor Transformations, Extraction of Li2SO4 from β-Spodumene, and Electrode Balancing

Ahmed, Sabbir (2026) From Lithium Ores to Battery Cells: Ore-to-Precursor Transformations, Extraction of Li2SO4 from β-Spodumene, and Electrode Balancing. Masters thesis, Concordia University.

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Abstract

The increasing demand for lithium-ion batteries (LIBs) reinforces the need for improved lithium production alongside durable, high-rate cell performance, with practical routes that can be implemented at industrial scale. This thesis integrates three complementary themes: lithium resource-to-precursor transformation, fluorine-assisted lithium extraction from β-spodumene, and electrode balancing for fast-charging LIBs. It first consolidates the main industrial routes used to produce battery-grade lithium salts (Li₂CO₃, LiOH·H₂O, and LiCl) from spodumene ores and brines, covering beneficiation, conversion, and brine recovery operations. In parallel, emerging direct extraction concepts are evaluated, emphasizing that selectivity toward Li⁺ and effective impurity control remain decisive barriers to reliable scale-up. The thesis then experimentally evaluates a fluorine-assisted roasting–washing–leaching pathway using β-spodumene concentrate. Roasting is conducted at 180 °C with increasing β-spodumene:NH₄F molar ratios (1:1.67 to 1:5.02), followed by sequential water washing and dilute-acid leaching. Lithium recovery is quantified by ICP analysis, and reaction-driven phase evolution is tracked by XRD and SEM. Lithium extraction increases systematically with fluoride dosage, reaching ~27% at the highest ratio, and correlates with progressive β-spodumene depletion and the formation of LiF together with aluminosilicate products (nepheline and albite). Finally, an electrode-level analysis identifies the negative-to-positive (N/P) capacity ratio as a critical LIB design parameter that governs SEI evolution, lithium plating risk, irreversible capacity loss, and long-term aging during fast charging. This combined perspective supports coherent mine-to-cell optimization and decision-making. Overall, the results highlight the value of integrating extraction chemistry with electrode balancing principles to advance safe, durable, and high-rate LIB technologies.

Divisions:Concordia University > Gina Cody School of Engineering and Computer Science > Chemical and Materials Engineering
Item Type:Thesis (Masters)
Authors:Ahmed, Sabbir
Institution:Concordia University
Degree Name:M.A. Sc.
Program:Chemical Engineering
Date:6 February 2026
Thesis Supervisor(s):Zaghib, Karim
Keywords:Spodumene, Brine, Lithium-ion Battery, N/P ratio, Cell balance, Li2CO3, LiOH
ID Code:996804
Deposited By: Sabbir Ahmed
Deposited On:29 Jun 2026 14:31
Last Modified:29 Jun 2026 14:31

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