Key considerations for the dissolution of metals and alloys in the production of battery grade metal sulfates

With the global transition towards electrification, the demand for battery metal sulfates is growing rapidly. One of the processing routes – metal dissolution, involving the dissolution of metals or alloys and produces battery-grade metal sulfates, is a strategic solution to help meet this increasing demand. The metal dissolution process provides a pathway for producers to swiftly enter the battery market and it is a proven and viable means for the production of metal sulfates. This paper discusses the key technical considerations for designing a metal dissolution processing plant from the raw metal feed through to the final, battery grade specification sulphate. The discussion encompasses various aspects, including (i) selection of metal feed and dissolution reactor types; (ii) description of key parameters that drive the dissolution process and its stability, (iii) development of the overall flowsheet to meet battery grade specifications and optimize costs; (iv) design of targeted experiments to study and de-risk critical areas of the process and identify suitable materials of construction; (v) sizing and scale-up considerations; and (vi) use of specialized analysis such as Computational Fluid Dynamics and Finite Element Analysis to assist in the design, scale-up, and technical de-risking.