Oct 16, 2026
Saltworks’ patented Generation‑II lithium processing flow sheet is making a substantial contribution to lowering the cost and boosting recovery for lithium brine-to-battery chemical projects.
The patented inventive leap combines open‑source direct lithium extraction (DLE) adsorbents and pressurized membrane systems in a novel configuration that boosts purity, reduces entropy, and eliminates wasteful lithium losses. The result is reduced capacity and fewer unit operations, with less chemical intensity, ultimately lowering both capital and operating costs.
DLE technology has struggled with commercial uptake in North America, largely driven by capital intensity, market conditions, and the lack of reliable full flow sheet proof points. Generation‑I flow sheets rely on single‑stage DLE, often producing a 60-70% pure eluate with appreciable scaling ions and boron content, which can significantly increase downstream processing costs.
Saltworks’ team developed, tested, and refined the Generation‑II flow sheet to achieve over 90% lithium purity relative to total cations. This low impurity profile, including substantially improved rejection of scaling ions and boron, enables simplified refining and concentration of eluate to over 20,000 mg/L lithium, the optimal range for carbonation, without the use of costly and chemically intensive softening, ion exchange system, and energy‑intensive evaporators. This materially lowers capital intensity and will help make DLE projects more cost-competitive and easier to finance, especially when combined with Project Aurora’s demo plant data.
The combined use of open‑source adsorbents and membranes in this novel configuration keeps processing chemical‑free and in the liquid phase, while also enabling efficient recycling of reject streams. In addition to reducing capital equipment, this approach improves overall lithium recovery while reducing requirements for chemical deliveries, waste management, labor, and operating complexity.
The projected result, based on detailed pilots and diligent engineering studies calibrated to Saltworks’ full-scale mineral and semiconductor processing plants, is the production of higher-purity lithium chloride at increased concentration, while reducing both chemical and capital requirements. A wellhead-connected continuous flow demonstration is nearing construction completion to prove and tune the system as well as the economics.
Saltworks’ open‑source delivery model reduces sole‑source supply chain dependence and drives competition. Saltworks’ goal is to make a meaningful contribution to the commercialization of cost-efficient and reliable fully integrated DLE-based lithium refining systems. During development of the Generation-II technology, which still progresses today, the team leveraged Saltworks’ full‑scale plant performance data, modularized manufacturing capabilities, supply chain, laboratory and pilots, digital twins, and process engineering expertise.
Based on direct comparative front‑end engineering design (FEED) studies completed with the same inputs, the Generation‑II system delivers 25% lower CAPEX, 40% lower OPEX, and 15% higher lithium recovery than Generation‑I flow sheets.
This work also revealed that the Generation‑II technology is particularly well suited to:
Saltworks is proud to demonstrate the technology with EMP Metals as part of Project Aurora in Saskatchewan. The patented technology is in continuous operation directly connected to a wellhead, with complete system automation and data capture. It is a smaller replica of Saltworks’ full-scale unit operations and advanced automation systems delivered at 20K TPA equivalent scale to major semiconductor projects. Aurora data will scale into lithium projects.
The Saltworks team is enthusiastic about contributing to improved competitiveness in DLE-based lithium refining systems by leveraging its process excellence, full-scale integrated modularized plants, manufacturing capabilities, and disciplined project delivery.
Saltworks Technologies is a leader in the development and delivery of solutions for industrial wastewater treatment and lithium refining. By working with customers to understand their unique challenges and focusing on continuous innovation, Saltworks’ solutions provide best-in-class performance and reliability. From its headquarters in Richmond, BC, Canada, Saltworks’ team designs, builds, and operates full-scale plants, and offers comprehensive onsite and offsite testing services with its fleet of mobile pilots.
Saltworks Technologies has expanded its advanced manufacturing operations by 70,000 square feet in Richmond, British Columbia due to increased demand of large-scale systems driven by the semiconductor, data center, and critical mineral industries.
EMP Metals Corp., Saltworks Technologies’ project partner on Project Aurora, has been awarded $1 million in funding from the Government of British Columbia’s Integrated Marketplace (IM) program, delivered by Innovate BC, as part of its recently announced Mining & Critical Minerals Testbed.
Saltworks launches SaltMaker MVR-30, doubling evaporation capacity to 30 TPH with patented intelligent automation for reliable ZLD and low maintenance.
Saltworks introduces its second-generation Direct Lithium Extraction (DLE) technology, featuring a unique double-DLE process that delivers 90% eluate purity and cuts capital costs by over 25%. Built on a patented design using alumina adsorbents and pressurized membranes, the system has undergone extensive trials and optimization.