Lithium is a critical mineral resource. With the development of high-end manufacturing industry, the demand for high-performance lithium-containing chemical raw materials continues to grow. At present, lithium needs to be acquired from a large amount of lepidolite ore, constrained by the existing lithium resource supply limitation quandary, and the industry urgently needs to develop more efficient beneficiation and extraction methods for lepidolite. Findings have suggested mixed collectors (e.g., DDA/SDBS) achieve a 4.99% Li₂O grade and 98% recovery at neutral pH, reducing reagent use by 20–30%. Microwave-assisted roasting boosts Li recovery to 95.9% and cuts energy use by 26.9%. Bioleaching with Acidithiobacillus ferrooxidans (A.F.) and rhamnolipid releases 6.8 mg/L Li with a lower environmental impact. Sulfuric acid baking recovers Li (97.1%), Rb (96.0%), and Cs (95.1%) efficiently. Despite challenges in fine-particle recovery and reagent costs, integrated strategies like nanobubble flotation, green collectors, and AI optimization offer sustainable, high-efficiency extraction. This work provides insights for advancing lepidolite processing, balancing economics and environmental stewardship.

In magnetic separation processes, the capture radius R_c of magnetic particles achieved by the magnetic matrix constitutes a critical parameter governing the separation efficiency and operational performance of magnetic separation equipment. Through a systematic study of the characteristics of R_c and the factors influencing it, the application capability of separation systems can be notably improved. To address the lack of systematic research on R_c under low magnetic field intensities (<0.6 T), a key gap compared to conventional high gradient magnetic separation (HGMS) operating at ≥0.6 T, the motion trajectories of magnetic particles adjacent to a rod-shaped matrix, as well as their final capture or repulsion behaviors, were observed via a high-speed camera. Concurrently, these processes were accurately reproduced using the finite element method (FEM). This study innovatively integrates experimental validation and FEM simulation, achieving mutual verification that single-method studies cannot provide. Based on the experimentally validated FEM model, the effects of magnetic field intensity H, rod-shaped matrix diameter Φ, magnetic particle diameter d, and fluid viscosity η on the motion of magnetic particles were methodically investigated. The velocity characteristics of particles at critical positions between the capture and repulsion zones were analyzed to determine the capture radius of the rod-shaped matrix under specified conditions. Drawing on the identified parametric effects, the developed capture radius prediction model fills the research gap in low-intensity HGMS and serves as a theoretical reference for optimizing both the spacing design of industrial-scale rod-shaped matrix arrays and their matching with relevant operating parameters, and the development of energy-efficient magnetic separation equipment.

China is rich in magnetite mineral resources, but they are generally characterized by low grade, fine dissemination size, and a high content of harmful impurities. Wet low-intensity magnetic separation (WLIMS) is an important method for processing fine-grained magnetite. However, during the separation process, fine magnetite particles are prone to magnetic agglomeration, which makes it difficult for conventional WLIMS separators to achieve high-selectivity separation. To address this issue, a novel WLIMS separator based on a rotating magnetic system was developed in this investigation, and its separation characteristics were systematically investigated through a combined approach comprising CFD–DEM–FEM multiphysics coupling simulations and experimental validation. Simulation results indicate that the rotating magnetic system significantly reduces the chain length and the structural stability of magnetic agglomerates just as magnetite particles enter the magnetic field region. Furthermore, under the rotating action of the magnetic system, the magnetic chains only enclose a portion of the intergrowth minerals, while gangue minerals remain unattached, which positively contributes to improved separation selectivity. Both laboratory-scale experimental results and industrial production data indicate that, compared to the conventional WLIMS separator, the rotating magnetic system WLIMS separator achieves significantly superior separation performance. For a magnetite ore with a grade of 57.68%, the rotating magnetic system WLIMS separator achieved an optimal concentrate grade of 65.43% (with a recovery of 94.78%), whereas the conventional WLIMS separator attained only 60.32% at a similar recovery rate. This investigation provides an important basis for the large-scale industrial application of rotating magnetic system WLIMS separators and the efficient development and utilization of fine-grained magnetite resources.