FRP and Dual Laminate Equipment for Lithium Extraction: Corrosion-Resistant Solutions for the Energy Transition

Corrosion Challenges in Lithium Production

Lithium is produced from several sources, including:

• Natural brines from salt lakes and salars
• Geothermal brines
• Hard-rock ores such as spodumene
• Recycled lithium-ion batteries
• Direct Lithium Extraction (DLE) processes

Many of these production routes involve highly corrosive process streams containing concentrated chlorides, sulfuric acid, hydrochloric acid, sodium hydroxide, and various extraction solvents.

In Direct Lithium Extraction systems, for example, adsorption and ion-exchange media are periodically regenerated using acidic stripping solutions. These regeneration cycles expose process equipment to aggressive chemical conditions that can rapidly degrade conventional metallic materials.

Several scientific reviews of modern lithium extraction technologies identify corrosion management as a key challenge for achieving long-term operational reliability and economic performance.

Why FRP is an Ideal Material for Lithium Processing Facilities

Fiber Reinforced Plastic combines glass fiber reinforcement with corrosion-resistant resin systems such as vinyl ester resins. The resulting composite material offers several advantages over traditional metallic alternatives:

• Excellent resistance to chloride-rich environments
• Superior performance in acidic and alkaline service
• Immunity to galvanic corrosion
• Low maintenance requirements
• Long service life
• Significantly lower weight compared to steel
• Reduced installation and foundation costs

FRP has been successfully used for decades in highly corrosive industries including chemical processing, hydrometallurgy, flue gas desulfurization, and wastewater treatment. These same advantages make FRP particularly attractive for lithium production facilities where corrosion resistance directly impacts plant availability and lifecycle costs.

When Dual Laminate Construction Provides Additional Benefits

While FRP performs exceptionally well in many corrosive applications, certain lithium processing streams require even higher levels of chemical resistance.

Dual Laminate construction combines:

• A thermoplastic corrosion barrier (PP, PE, PVC, ECTFE, PVDF, or PTFE)
• A structural FRP outer shell that provides mechanical strength

This hybrid design combines the excellent chemical resistance of thermoplastics with the structural capabilities of FRP.

For lithium extraction and refining facilities, Dual Laminate equipment is often selected for applications involving:

• Highly concentrated acids
• Aggressive chloride solutions
• Solvent extraction circuits
• Elevated operating temperatures
• Continuous exposure to stripping and regeneration chemicals

Depending on the selected thermoplastic liner, Dual Laminate systems can withstand some of the most demanding chemical environments found in modern hydrometallurgical processing plants.

Applications in Lithium Extraction and Refining Facilities

Storage Tanks

Lithium processing facilities typically require large storage capacities for:

• Raw brines
• Sulfuric acid
• Hydrochloric acid
• Sodium hydroxide
• Eluate solutions
• Process water
• Wastewater streams

FRP tanks provide a cost-effective and corrosion-resistant solution for large-volume storage. For more aggressive chemical services, Dual Laminate tanks offer enhanced protection while maintaining the economic benefits of composite construction.

Scrubbers

Gas treatment systems play an essential role in environmental compliance and process safety within lithium production facilities.

Process emissions may contain:

• Acidic vapors
• Chloride-containing gases
• Solvent vapors
• Chemical reaction by-products

FRP and Dual Laminate scrubbers offer outstanding resistance to these corrosive gas streams while minimizing maintenance requirements and extending service life.

For hydrochloric acid and sulfuric acid gas treatment applications, thermoplastic-lined Dual Laminate scrubbers are often the preferred solution.

Absorbers

Absorption columns are widely used in gas treatment, solvent recovery, and chemical purification processes.

Because absorbers are often large-diameter, tall structures, the low weight of FRP provides significant advantages during transportation, installation, and structural design.

Dual Laminate absorbers further enable reliable operation in highly corrosive environments where metallic alternatives would require expensive exotic alloys or frequent maintenance interventions.

Stripping Columns

Stripping is a critical step in many Direct Lithium Extraction processes. During this stage, lithium is recovered from adsorption media or extraction systems using acidic stripping solutions.

These process conditions place severe demands on materials of construction due to:

• Low pH values
• High chloride concentrations
• Elevated temperatures
• Continuous chemical exposure

Dual Laminate stripping columns provide excellent long-term resistance to these conditions while maintaining structural integrity and minimizing lifecycle costs.

Piping Systems

Piping networks form the backbone of every lithium production facility, transporting process fluids throughout extraction, purification, and refining operations.

FRP and Dual Laminate piping systems are commonly used for:

• Brine transfer lines
• Acid distribution systems
• Caustic service
• Solvent transport
• Wastewater handling
• Chemical dosing systems

Unlike metallic piping, composite piping systems are not susceptible to pitting corrosion or chloride stress corrosion cracking, both of which are common failure mechanisms in lithium processing environments.

Supporting the Future of Lithium Production

As lithium producers seek to improve plant reliability, reduce maintenance costs, and maximize operational uptime, material selection continues to play an increasingly important role in facility design.

Scientific literature on Direct Lithium Extraction and advanced lithium refining technologies consistently highlights the challenges posed by aggressive chemical environments. At the same time, industry experience continues to demonstrate the effectiveness of FRP and Dual Laminate equipment in overcoming these challenges.

By combining exceptional corrosion resistance with low lifecycle costs and long service life, FRP and Dual Laminate systems provide a future-proof solution for tanks, scrubbers, absorbers, stripping columns, and piping systems throughout the lithium value chain.

Plasticon Projects: Your Partner in Corrosion-Resistant Lithium Processing Equipment

Plasticon Projects designs, manufactures, and installs large-scale FRP and Dual Laminate equipment for demanding industrial applications worldwide.

With decades of experience in corrosion-resistant process equipment, we support lithium extraction and refining projects with custom-engineered solutions including:

• Storage tanks
• Scrubbers
• Absorbers
• Stripping columns
• Process vessels
• Piping systems

Our expertise in both factory fabrication and on-site construction enables us to deliver reliable composite solutions for even the largest and most complex lithium processing facilities.