Beneficiating the low-grade lithium ores to remove the gangue minerals and enhancing their grade is an attractive proposition today. The beneficiation of a low-grade spodumene ore from Eastern Kazakhstan is investigated by dense media separation (DMS) and froth flotation to obtain a concentrated lithium product. DMS processed the −1000/+850 µm and −850/+500 µm size fractions, while fine particle of −74/+38 µm of composite samples was carried out by froth flotation. The lithium content of the ore varies between 0.3 and 0.5% Li₂O. In the 1000/+500 µm size fraction of DMS testwork, the highest lithium grade of 6.7% was achieved with a recovery rate of about 35% at a separation specific gravity of 3.0, while 90% of the lithium oxide was recovered in 8% of the mass, with a grade of 5.1% Li₂O at a separation specific gravity of 2.8. Most of the gangue (over 90%) was effectively removed at a specific gravity of 2.7 for both coarse size fractions. A maximum lithium recovery of approximately 53% with a highest lithium grade of 1.2% was obtained under reverse flotation condition of 1000 g/t NaOL/DAA, mixture ratio of 1:5, pH 10, and dextrin concentration of 4000 g/t. The zeta potential and XPS measurements revealed that the mixed NaOL/DAA system exhibited limited interaction with the spodumene surface, primarily through weak chemisorption and electrostatic adsorption, which led to a reduction in the thickness of the DAA multilayer. Graphical Abstract

Lithium, a critical element for clean energy and modern technologies, plays an indispensable role in advancing renewable energy storage, electric vehicles, and high-tech industries. The rapidly growing demand for lithium, along with its limited global production, has led to concerns about the sustainability of current extraction and processing technologies for efficient lithium recovery. This comprehensive review explores global trends in lithium processing, focusing on spodumene beneficiation and extraction techniques. While highlighting well-established conventional processes, such as dense media separation (DMS), flotation, high-temperature roasting, and acid or alkali treatment, it underscores the environmental and economic challenges of these processes, particularly when applied to low-grade lithium ores, which are increasingly being targeted to meet lithium demand. Innovative methods, such as microwave irradiation, are also explored for their potential to improve process efficiency, reduce energy consumption, and minimize environmental impact, offering promising pathways to overcome the limitations of traditional lithium recovery techniques. A significant contribution of this review is its focus on the largely untapped lithium resources of Kazakhstan, presenting geological insights and the potential for sustainable development. By addressing knowledge gaps and integrating technological, eco-friendly, and regional development perspectives, this study provides valuable insights for advancing lithium processing toward more sustainable and circular practices aligned with global climate and resource efficiency goals.

This study presents a sustainable approach for processing low-grade lithium-bearing aluminosilicate ores via carbothermic treatment with selective lithium stabilization in the slag phase. The proposed method is based on controlled phase transformations that suppress lithium volatilization and promote its retention in the condensed phases. Thermodynamic analysis revealed that lithium volatilization is unfavorable within a defined temperature window, enabling its stabilization in the slag. Experimental smelting, conducted at 1550–1600 °C with the addition of an iron-bearing component, resulted in the selective reduction of silicon and aluminum into a ferro silicon aluminum alloy, while lithium was efficiently concentrated in the slag phase. Lithium recovery to the slag reached up to 94%, with losses to the gas phase below 6%, demonstrating a significant reduction in volatilization compared to conventional high-temperature processes. X-ray diffraction (XRD) analysis confirmed that lithium is predominantly immobilized in the form of LiAlSiO₄ (pseudo-eucryptite), which enhances the chemical reactivity of the slag. From a sustainability perspective, the proposed process enables efficient utilization of low-grade lithium resources, minimizes lithium losses, and eliminates the need for energy-intensive pre-treatment steps such as roasting or vacuum processing. The resulting lithium-bearing slag represents a reactive intermediate suitable for subsequent hydrometallurgical extraction, enabling an integrated and resource-efficient process route. The results demonstrate that phase-controlled carbothermic processing is a viable and sustainable strategy for lithium recovery from low-grade aluminosilicate ores.

This study investigated the production of spodumene concentrate and lithium carbonate from a low-grade pegmatite ore containing approximately 0.26 wt.% Li₂O. The ore consisted predominantly of a quartz–feldspar aluminosilicate matrix with dispersed spodumene mineralization, which complicates conventional processing approaches. Preliminary lithium concentration was performed by dense media separation (DMS) using an industrially applicable ferrosilicon-based suspension. The highest separation efficiency was achieved for the −4.0/+2.8 mm fraction, producing a DMS concentrate containing 5.77 wt.% Li₂O with 98% lithium recovery. The obtained spodumene concentrate was subjected to decrepitation at 1000–1100 °C to convert α-spodumene into the more reactive β-modification, followed by sulfation roasting with concentrated sulfuric acid at 250–270 °C. The productive leach solution obtained after water leaching contained up to 12.1 g/L Li₂O. After purification from iron-bearing impurities and precipitation with sodium carbonate, a lithium carbonate product containing at least 98.8 wt.% Li₂CO₃ was obtained. Approximately 53% of the lithium contained in the original ore was recovered into the DMS feed fraction, whereas the overall lithium recovery into lithium carbonate reached about 45% relative to the ore and approximately 70% relative to the concentrate.