Spodumene concentrators, DMS circuits, lithium hydroxide trains

    Commissioning software for lithium plants where a DMS circuit, a concentrator and a hydroxide conversion train each run to a different chemistry.

    Battery minerals projects stack a spodumene concentrator's crushing, dense media separation and flotation circuits against a downstream lithium hydroxide or carbonate conversion train's roasting, leaching and crystallisation reactors, often on the same site and the same schedule. Deskely tags each circuit and reactor train separately, so mechanical completion, wet commissioning and ramp-up to nameplate recovery are tracked against the chemistry each stage actually depends on.

    Circuits
    Crushing, DMS, flotation, conversion
    Test
    Wet commissioning, recovery ramp-up
    Chemistry
    Spodumene to hydroxide/carbonate
    Gate
    Nameplate recovery and product spec
    DLE PLANT — CIRCUIT 2LITHIUM PROCESS RECORD SET · REV ADMS PLANT — SPODUMENEFLOTATION CIRCUITHYDROXIDE CONVERSIONCAUSTIC ROASTERLiOH-BATCH-14Purity assay pendingTAG REGISTERDLE-COL-02Direct lithium extraction…Records signedEVAP-04Multi-effect evaporator, …In testLICO3-CRY-01Lithium carbonate crystal…PreservationACID-DOS-06Hydrochloric acid dosing …Punch open18 columnsunder one system hierarchy

    The problem

    A concentrator and a conversion plant ramp up on completely different timelines, on the same site.

    A spodumene concentrator's crushing, screening, dense media separation and flotation circuits are commissioned wet, cell by cell, chasing a lithium recovery curve that depends on ore variability from day one of ramp-up.

    A downstream lithium hydroxide or carbonate conversion train — roasting kilns, acid leach, impurity removal, crystallisers and dryers — is commissioned against a chemical process specification with its own reagent handling, corrosion-resistant materials and product purity gates, often years or phases apart from the concentrator.

    Deskely tags the concentrator circuits and the conversion train as separate process areas with their own commissioning sequences, so a construction and process team is not forced to report both on one generic 'plant commissioning' percentage that hides which chemistry is actually behind schedule.

    CHEMISTRY RISK NO SPREADSHEET CATCHESLithium conversion plantHigh-hazard chemical unit ops feeding a battery-grade purity specAcid/alkali handling area MOC reviewsignedLithium chemical plant HAZOP closeoutsignedBattery-grade purity assay verificationoutstandingReagent storage and spill containment testoutstandingBATTERY-GRADE SPEC WON'T CLOSE UNTIL PURITY IS PROVEN99.5%target Li2CO3 purity, not yet assayed2MOC/HAZOP items still openDeskely ties MOC, HAZOP closeout and purity assays to the same unit op tag.

    Setting up the register

    Crushing, DMS, flotation and conversion are structured as the distinct process areas they are.

    Crushing and screening, dense media separation cyclones and drum separators, flotation cells and tailings handling are tagged as concentrator subsystems, each with pre-commissioning, wet commissioning and performance testing stages.

    The hydroxide or carbonate conversion train is tagged separately by unit operation — roaster, leach tanks, solvent extraction or ion exchange, crystallisers, centrifuges and dryers — reflecting the P&IDs and process description rather than a generic plant structure.

    Vendor process guarantees, reagent handling data sheets and materials of construction requirements are parsed into the register, so corrosion-critical equipment is flagged for extra inspection ahead of first reagent introduction.

    1 · SOURCE DOCUMENTSProcess flow diagrams re…48 sheetsDLE column equipment list18 columnsInstrument loop schedule1,240 loopsReagent and acid dosing …22 stationsPARSE + MATCHtag · description · drawing ref2 · ONE TAG REGISTERDLE-COL-02Direct lithium extraction…DLE CIRCUITEVAP-04Multi-effect evaporator, …CONCENTRATIONLICO3-CRY-01Lithium carbonate crystal…CONVERSIONACID-DOS-06Hydrochloric acid dosing …REAGENTSTWO DOCUMENTS DISAGREEProcess flow diag…Lithium carbonate crystalli…DLE column equipm…Abbreviated descriptionEngineer picks the sourcedecision loggedWeeks of transcription become a draft an engineer reviews.

    Execution

    Wet commissioning and recovery ramp-up are tracked against ore variability, not a fixed test date.

    Concentrator wet commissioning runs ore through the DMS and flotation circuits with lithium recovery, concentrate grade and moisture logged per shift against the tag, so a metallurgist can see whether a shortfall traces to crusher throughput, DMS media density or flotation reagent dosing.

    Conversion train commissioning introduces reagents in a controlled sequence, with hazardous chemical handling checks, PPE and interlock verification captured before roasting or leaching begins, and product purity samples logged against each crystalliser batch.

    Vendor punch lists from the concentrator OEM and the conversion process licensor are tracked separately, since a concentrator mechanical defect should not block conversion train ramp-up and vice versa.

    CHEMICAL PLANT START-UP GATE LADDERLithium conversion — reactor train 1MOC review and HAZOP closeout100%No-load reactor commissioning100%Reagent handling and spill containment test55%First production run, purity sampling25%Battery-grade spec sign-off0%2 of 5gates cleared0gates skipped without evidenceBattery-grade sign-off waits on assayed purity, not a scheduled start date.

    Ramp-up to nameplate and handover

    Nameplate recovery and product spec are proven circuit by circuit, before the whole plant is called complete.

    Mechanical completion and RFSU are issued per circuit and unit operation, with performance testing against guaranteed recovery, grade and product purity run and signed independently for the concentrator and the conversion train.

    Statutory sign-off for dangerous goods storage, reagent handling and pressure equipment in the conversion train is captured against the same register used for process commissioning, satisfying the site's major hazard facility obligations without a parallel file.

    The handover pack for the metallurgical and process teams includes wet commissioning recovery curves, product assay history and vendor performance test certificates per circuit, giving operations a documented baseline for the first full quarter of production.

    DLE circuit 2 — ramp-up ladderFeed authorisation issues only from signed wet-comm evidenceMCMechanical completionRecords signed 03 OctColumn installation records18 / 18 signedLoop checks closedcompleteWCWet commissioningIn test — process teamWater run completeconfirmedResin loading verifiedconfirmedRURamp-up to feedPunch open — 5 itemsBlocking punch5 openPlant manager sign-offnot witnessed

    Battery-grade product certification for offtake

    A lithium hydroxide batch that hits the target assay still fails the offtake spec if a trace impurity nobody was tracking comes in over limit.

    Battery-grade lithium hydroxide and carbonate offtake agreements specify tight limits on trace impurities — iron, calcium, magnesium, sodium and sulphate — well beyond the headline lithium content, and a crystalliser or centrifuge batch that looks compliant on the primary assay can still be rejected by a cathode manufacturer's incoming QC on a single trace element.

    Because the impurity limits are often tighter than anything the concentrator or conversion plant's own process control philosophy was originally designed around, first-batch product certification tends to expose gaps between what the plant's instrumentation actually measures and what the offtake contract requires as certified evidence.

    Deskely records each conversion train batch's full impurity panel against its crystalliser or centrifuge tag, alongside the sampling and lab chain-of-custody record, so a product certification pack for the offtaker is assembled from the same register as the mechanical commissioning evidence rather than reconciled separately by the marketing team against a lab spreadsheet.

    TWO CHEMISTRIES, TWO SCHEDULES, ONE SITEConcentrator + conversion trainA concentrator punch item should never gate the conversion train's ramp-up, or vice versaSPODUMENE CONCENTRATORCrushingwet commissionedDMS circuitwet commissionedFlotationin testHYDROXIDE CONVERSION TRAINRoastingreagent provenLeach + SX/IXMOC openCrystallisersMOC open99.5% Li2CO3 purity target — not yet assayed, gated on its own product specRecovery, grade and purity are tracked separately per circuit, never blended into one numberDeskely keeps the concentrator and the conversion train on independent ramp-up evidence.

    How it runs

    From spodumene ore to battery-grade product, tracked as separate chemistries.

    A concentrator and a conversion train are two different plants wearing one project name, and the register has to keep them that way.

    1. 01

      Tag by process area

      Crushing, DMS, flotation and each conversion unit operation registered as its own subsystem with its own commissioning sequence.

    2. 02

      Wet commission with ore

      Recovery, grade and moisture logged per shift against the DMS and flotation circuits to trace shortfalls to their source.

    3. 03

      Introduce reagents under control

      Hazardous chemical handling and interlock checks captured before roasting and leaching begin, with product purity logged per batch.

    4. 04

      Certify recovery and spec independently

      Performance testing and statutory sign-off issued per circuit, so concentrator and conversion train ramp-up on their own evidence.

    FAQ

    Questions about Lithium and battery minerals scopes.

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