Grade Nickel Research Articles

Reduction of limonite ore from South Sulawesi with additive Na2SO4 using carbon monoxide

ABSTRACT This study utilised a selective reduction method to generate ferronickel from limonitic ore, followed by a magnetic separation stage. The research explored the kinetics and the influence of time and temperature on nickel content and recovery. Sodium sulfate was incorporated as an additive, and carbon monoxide (CO) gas served as the reductant in a vertical tube furnace. Magnetic separation employed a permanent magnet set at 500 G. Reduction took place at temperatures of 900°C, 1000°C, and 1100°C, with varying durations from 30 min to 180 min. Optimal recovery and nickel grade were achieved at 1100°C for 180 min, reaching 70.07% and 8.49%, respectively. Increasing the reduction temperature and time correlated with enhanced recovery and nickel grade.

Comparative study of Ni nanoparticles synthetized using electroless Ni plating waste and an analytical Ni reagent. Characterization and possible application in magnetic fluids

Wastewater from the electroless industry represents a potential danger to the environment and health, mainly due to its heavy metal content. In this study, nickel nanoparticles were synthesized through chemical reduction precipitation by using an electroless nickel plating waste and hydrazine sulfate as reducing agent. The aim of the present work is twofold. First we want to extract the metal from the aqueous medium, minimizing its content to levels allowed by environmental regulations. Second, we aim to valorize the residue by recovering the precipitated nickel to be applied as a solid phase in a magnetic fluid (MF). It is found that the present synthesis method using N2H4 as reducing agent, allowed us to minimize the Ni concentration in the aqueous waste in 97.49 %. The properties of the recovered Ni precipitate is compared with the Ni nanoparticles (NPs) obtained from a solution prepared with analytical grade nickel sulfate. The synthesized materials from both the waste (Ni-R) and analytical reagent (Ni-A) were characterized by comparing their chemical, physical, and morphological properties. In both cases, the Ni-R and Ni-A precipitates, spherical Ni NPs of 8–10 nm crystallite sizes are obtained, agglomerated in a bimodal size distribution centered at 174.6 and 383.4 nm, and a monomodal size distribution centered at 63.6 nm, respectively. Both Ni precipitated samples are ferromagnetic, but the Ni-R sample has a higher magnetic saturation of 40 emu/g compared to 8 emu/g of the Ni-A sample. The difference in the rheological behavior of both precipitates could be attributed to the presence of surface oxidation having a relatively less contribution in the case of the Ni-R particles due to the higher average size of the particles. The Fe content, probably coming from the nickel-plated parts in spent baths, is slightly higher in the Ni-R sample. Thus, the present work shows that it is possible to valorize an industrial Ni-based residue, by obtaining Ni precipitates that in magnetic fluids give even better results than those expected under more rigorous experimental conditions, i.e., in cases where the quality of the chemical precursors is usually a determining factor.

Structure and properties of powders obtained by electrodispersion of pure Nickel metal waste in distilled water

Purpose. Investigation of the composition, structure and properties of powder materials obtained by electrodispersion of nickel waste of the PNK-0T1 brand in an oxygen-containing medium – distilled water.Methods. To determine the composition, structure and properties of powder materials, samples of powders obtained from waste nickel grade PNK-0T1 were studied. The powder material was obtained by electroerosive dispersion in distilled water. Microanalysis of powder particles was carried out using a scanning electron microscope, an analysis of the size distribution of powder particles was obtained using a particle size analyzer, an X-ray spectral microanalysis of powder particles was carried out using an energy-dispersive X-ray analyzer embedded in a scanning electron microscope, an analysis of the phase composition of powder particles was carried out using X-ray diffraction on the diffractometer.Results. During the study, it was revealed that the shape of the particles obtained from nickel powders is spherical and elliptical, and agglomerates of smaller particles are also noted on the increase. Oxygen and nickel are present in the composition of powder materials. The phases of pure nickel and nickel oxide NiO are marked in the phase composition. From the analysis of the granulometric histogram, it follows that the particle size spread varies in the range of 0.26...18.62 microns, the average volume diameter of the particles was 5.2 microns.Conclusion. The obtained research results can be used to develop a new heavy pseudo-alloy using metal waste from expensive raw materials by the method of electroerosive dispersion, followed by improvement and optimization of the composition and structure of the alloy.

Cradle to gate life-cycle assessment of battery grade nickel sulphate production through high-pressure acid leaching

The rising global demand for high-purity nickel (Ni) sulphate, primarily used in lithium-ion batteries, is largely met by processing Indonesian laterite ores via hydrometallurgy. However, this supply chain is associated with significant environmental challenges and lack of transparent industrial data. This study uses a cradle-to-gate life cycle assessment (LCA) approach to quantify the greenhouse gas (GHG) emissions and energy use associated with the production of mixed hydroxide precipitate (MHP) from low-grade Indonesian laterites via high-pressure acid leaching (HPAL), which is then refined in China for the production of battery-grade nickel sulphate hexahydrate (NiSO4·6H2O, NSH). Fifteen impact categories are analyzed using established impact assessment and allocation (mass and economic) methods. The analysis reveals that feed preparation/HPAL and purification are the stages that contribute most to environmental impacts and in particular to global warming potential (GWP). Mass allocation results in higher environmental impacts, with 36.8 kg CO2-eq per 1 kg of Ni in NSH for GWP, compared to 33.8 kg CO2-eq per 1 kg of Ni in NSH when economic allocation is used. Sensitivity analysis shows a potential reduction (up to 13 %) in key impact categories if production of NSH is fully integrated in Indonesia or a greener electricity mix is used. Overall, our results indicate that the production of MHP in Indonesia and its refinement to NSH in China has a GWP about two times higher than the global average. Given the limited number of LCA studies for the production of battery-grade nickel, this study highlights major environmental concerns for the NSH production process from Indonesian laterites and identifies opportunities for improvement, towards a more sustainable global battery supply chain.

Process Design for Direct Production of Battery Grade Nickel Sulfate

The clean energy transition has increased the global demand of nickel sulfate used in the Li-ion batteries. A short-term solution is to refine the nickel sulfate product from nickel intermediates. In the long-term, new direct nickel sulfate production technologies are needed. This research focused on the modeling-based concept development of a novel direct hydrometallurgical nickel sulfate process consisting of chemical leaching, impurity removal by precipitation, solvent extraction, and crystallization as an alternative to the conventional nickel sulfate production route via a nickel matte intermediate. The conventional process route with the studied nickel concentrate had lower chemical consumption and waste production compared to direct hydrometallurgical process where approximately 60% of iron was leached consuming oxygen, and the following iron precipitation step consuming calcium carbonate resulted in a high amount of iron precipitate together with gypsum. However, hydrometallurgical alternatives are often suitable for lower ore grades or volumes and can recover copper as by-product metal. The biggest impacts on carbon footprint from chemical consumption in the direct hydrometallurgical process were generated in iron precipitation and oxygen use in leaching. With the studied nickel concentrate, pyrrhotite played a key role in both oxygen use and iron precipitation. In the leaching step, 68% of total oxygen consumption was related to pyrrhotite leaching, while in iron removal 73% of total iron originated from pyrrhotite. Thus, especially pyrrhotite removal prior to leaching needs to be developed to reduce the carbon dioxide footprint, when the pyrrhotite content in the material is high.Graphical

Effect of pH on Precipitation of Ferronickel Leaching Solution by Using MgO for Mixed Sulfate Precipitate Synthesis

The increasing demand for electric vehicles affects the high demand for nickel-based batteries, including Nickel Manganese Cobalt (NMC) batteries. Generally, NMC is processed from high-quality ore (sulfide ore) to produce nickel (II) sulfate hexahydrate or NiSO4.6H2O. But sulfide ore face scarcity due to a long history of mining and exploitation. Thus, laterite-type nickel ore can be an alternative to nickel resources. This study aims to produce mixed sulfate precipitates from a ferronickel leaching solution that can be utilized further to produce NiSO4.6H2O. Also, this research will study the pH effect of the precipitation process on the product's elemental composition, recovery, and compounds formed. The precipitation process was conducted using 5% MgO (weight basis) with a pH range of 2.5 to 6.5 with one increment. The mixed sulfate precipitates were characterized using AAS, EDX, and XRD. When using a pH of 3.5, a nickel concentration of 1473.00 ppm, nickel recovery of 23.02%, and Nickel grade of 3.18% could be obtained. As a result, the phase of NiSO4.6H2O was formed. Also, the other phases were formed after precipitation, such as CoSO4, FeSO4, and MgSO4.

X-ray Fluorescence Analysis of the Elemental Composition of Tungsten, Nickel and Copper

The purpose of this work was to conduct an X-ray fluorescence analysis of the elemental composition of tungsten, nickel and copper metal waste using an Olympus Delta portable spectrometer.Methods. To determine the chemical composition of raw materials, samples of metal waste in the form of copper rods, tungsten rods of various diameters and scraps of nickel plates intended for recycling were examined. To determine the elemental composition of metal waste, the method of X-ray fluorescence analysis (XFA) was chosen. The X-ray fluorescence method is based on the ratio of the intensity of X-ray fluorescence to the concentration of elements in the sample. Samples irradiated with powerful X-ray tube radiation, in response, emit characteristic fluorescent radiation of atoms proportional to their concentration in the sample. This method allows us to qualitatively assess the elemental composition of complex samples without violating their physico-chemical properties with minimal time costs. The Olympus Delta spectrometer was used as an express analyzer of metals and alloys, with the help of which experimental data on the composition of metal waste of tungsten, nickel and copper were obtained.Results. Based on the conducted studies aimed at X-ray fluorescence analysis of the elemental composition of tungsten, nickel and copper metal waste using the Olympus Delta portable spectrometer, it was found that the samples of the studied metal waste correspond to the following grades of alloys: tungsten rod made of tungsten grade VA; nickel plate made of nickel grade PNK-0T1; copper rod made of copper grade M3r.Conclusion. The results obtained will allow further research on their processing by the method of electroerosive dispersion and reuse in the production of heavy tungsten alloys. Renovation of metal waste, including tungsten, nickel and copper metal waste, will contribute to resource conservation, import substitution and ensuring the technological sovereignty of the Russian Federation.

Water quality impact on flotation Response: A focus on specific ions and temperature

Plant water recycling causes an accumulation of ions in the process water which may affect plant processes since processing routes are water intensive. Seasonal temperature differences affect the water quality through variation of the available recycled water within the plant between the summer and winter seasons. The objective of this study was therefore to investigate the effect of specific ions and temperature, relevant to onsite process water recycling and temperature variations brought about by seasonal changes, on the separation of gangue from valuable minerals in batch flotation of a low-grade Cu-Ni-PGE ore. Water and solids recoveries were impacted by Ca2+ and SO42-. At high SO42- concentrations, an increase in Ca2+ increased the mass of water and solids recovered. An increase in SO42- alone caused an increase in copper recovery whilst decreasing the copper grade. S2O32- alone affected the nickel recovery. An increase in S2O32- caused an increase in nickel recovery whilst the nickel grade was affected by the interaction of S2O32- and temperature. Furthermore, copper showed similar trends as those observed for nickel in the responses for the mineral grade. At high S2O32- concentration there was no observable change in the nickel and copper grades when temperature increased. At low S2O32- concentrations, an increase in temperature decreased the nickel and copper grades. In addition to the interactive effect of temperature and S2O32-, nickel was more temperature sensitive in comparison to copper. The study demonstrated that there are specific ion concentration ranges beyond which flotation performance was adversely affected and other ranges beyond which no observable effect on flotation was visible. Based on this understanding, it may be possible to predict the ideal operating conditions for the number of water recycles in a plant. The higher ionic concentrations and their corresponding ionic strengths resulted in a more stable froth in comparison to lower ionic concentrations and consequently an improvement in the recoveries.

Enhancing nickel grade and recovery with counter-current washing of the concentrated bubbly-zone of a single stage REFLUX™ Flotation Cell

The recovery and concentration of the nickel sulphide mineral, pentlandite, present several challenges due to its relatively slow flotation, leading to excessive hydrophilic gangue minerals in the concentrate. The REFLUX™ Flotation Cell (RFC™) offers the potential for a significant hydrodynamic advantage over conventional flotation. Much of this advantage is due to the replacement of the pulp and froth phases with a concentrated bubbly zone, which in turn supports more intense counter-current washing by permitting a powerful and effective positive bias flux. Thus, the aim of this study was to investigate the nickel recovery and silica rejection in the RFC™, by applying a wide range of positive bias fluxes. The focus was on a single stage of separation in the RFC™ using a feed flux of 0.63 cm/s at a feed nickel grade of 2.1%. At the lowest bias flux of 0.1 cm/s, a nickel grade of 7.5% was obtained at a single stage recovery of 70.2%. By increasing the bias flux to 0.42 cm/s, the grade increased to 9.7% but the recovery fell to 64.9%. With an extreme bias flux of 1.04 cm/s, the grade reached 12.3%, while the recovery fell to 54.7%. The selectivity, given by the nickel recovery relative to the silica recovery, was estimated to be 121 at the highest bias flux, declining sharply with a reduction in the bias flux. The performance ratio proposed by Parkes et al (2022) was quantified by comparing the RFC™ performance with the batch kinetic results from a mechanical cell, the product grade being ∼7%. The performance ratio was based on the experiment at the lowest bias flux used in the RFC™, and found to be at least 6, meaning the RFC™ footprint would be reduced by a factor of ∼6 for a similar product grade. Based on the higher product grades achieved in the RFC™ using the higher positive bias fluxes, the performance ratio would likely exceed 10-fold given the need for the mechanical cell concentrate to undergo at least one further stage of flotation.

Study on the Medium-Temperature Reduction Behavior of Methane and Laterite Nickel Ore

Under the background of carbon peaking and carbon neutrality, compared with a traditional carbon thermal reduction to produce nickel, gas-based reduction has outstanding advantages in efficiency and carbon reduction. However, there are few studies on gas-based reduction at present. This article explores the reduction behavior of methane on laterite nickel ore. The effects of different reaction temperatures, reaction times and gas concentrations on the reduction reaction were studied. The phase and morphology of laterite nickel ore and its calcined products were analyzed by XRD, SEM-EDS and gas chromatography. The results show that when the reduction temperature is 900 °C, the reduction time is 60 min, and the concentration of CH4 is 50%, a concentrate with a nickel grade of 3.06% and a recovery of 52.09% can be obtained. After analysis, the reason for the low nickel grade and recovery rate in the concentrate is, on the one hand, due to the incomplete reduction of NiO, and a large amount of nickel still exists in the silicate in the tailings; on the other hand, it is due to the fine grain size of the partially reduced nickel iron alloy, which is lost in the tailings and filtrate.

High-Grade Ferronickel Concentrates Prepared from Laterite Nickel Ore by a Carbothermal Reduction and Magnetic Separation Method.

Nickel is widely used in industrial processes and plays a crucial role in many applications. However, most of the nickel resource mainly exists as nickel oxide in laterite nickel ore with complex composition, resulting in difficulty in upgrading the nickel content using physical separation methods. In this study, high-grade ferronickel concentrates were obtained through a carbothermal reduction and magnetic separation using laterite nickel ore and anthracite as raw materials. The effects of different types of additives (CaF2, Na2SO4, and H3BO3), carbon ratio (the molar ratio of oxygen atoms in the laterite nickel ore to carbon atoms in anthracite), and grinding time on the recoveries and grades of ferronickel concentrates were experimentally investigated, along with the microstructure and chemical composition of the products. CaF2 was proved to be the primary active additive in the aggregation and growth of the ferronickel particles and the improvement of the grade of the product. Under the optimal conditions of CaF2 addition of 9.85 wt%, carbon ratio of 1.4, and grinding time of 240 s, high-grade magnetically separable ferronickel concentrate with nickel grade 8.93 wt% and iron grade 63.96 wt% was successfully prepared. This work presents a practical method for the highly efficient recovery and utilization of iron and nickel from low-grade laterite nickel ore, contributing to the development of strategies for the sustainable extraction and utilization of nickel resources.

Comparative Analysis of Mixing High Grade Limonite and Low Grade Saprolite Nickel Ore to Meet Market Demand at PT Mandiri Mineral Perkasa

PT Mandiri Mineral Perkasa is a contractor company operating in the field of nickel mining and has fulfilled the market/smelter demand requirements for Ni 1.5% - 2.0%, by setting a Cut Of Grade (COG) collection limit of Ni 1.4%. The aim of this research is to determine the Ni content of high grade limonite and low grade saprolite at the research location, and to determine the Ni content of high grade limonite and low grade saprolite, and to determine the additional tonnage and levels to meet market demand. In this study, the blending method was used, a mixing process between different low grade and high grade nickel ores to obtain appropriate mixture results, so that from the results of blending/mixing high grade limonite nickel ore, Ni 1.43 and Fe 26.71% were obtained, and for low grade saprolite you get 1.59% Ni and 26.73% Fe, for the results of blending/mixing high grade limonite and low grade saprolite you get 1.51% Ni and 26.72% Fe, efforts can be made to meet demand Ni 1.8% market with 5,000 tons needs to increase the grade and tonnage, namely, Ni grade 2.32% and 2,111.45 tons.

The Effect of Reductor Type in Thermal Upgrading of Limonite

Thermal upgrading is the process for nickel extraction in selective reduction with holding temperature in low (300-500 °C). The effect and type of reductor are the main factor during this process. With those factors, this research will be finding the variation of reductor type. The first step is limonite and reductor characterization. Ni, Fe, Mg, Al, and Si levels in limonite are 1.4 Ni, 50.5 Fe, 1.81 Al, 4.86 Mg, and 16.5 Si weight percent, respectively. The iron oxide/oxyhydroxide content of limonite is 94.4 percent and 5.6 percent silicate. For reductor, those are graphite, palm kernel shell, and anthracite with carbon percentage 98, 77, and 68 %. From XRF, the optimum nickel grade is in the graphite and anthracite with 6.5 and 7 wt%. For phases, the ferronickel is appearing in the high intensity for the optimum reductor type and the microstructure is around 5-10 um for both. Moreover, the optimum reductor type are graphite and anthracite. Keyword: reductor type, limonite, phase, microstructure, thermal upgrading.

Simultaneous dissolution of nickel, copper and cobalt from low grade nickel matte by (NH4)2S2O8-H2SO4 oxidative leaching

This study proposes a novel process for simultaneous extraction of valuable metals by oxidative leaching of low grade nickel matte in a mixed solution of (NH4)2S2O8 and H2SO4. The effects of some factors, such as particle size of matte, stirring speed, leaching time, leaching temperature, mass ratio of ammonium persulfate to matte (A/M) and sulfuric acid concentration, on metal extraction in the leaching process were systematically investigated. The way of adding saturated ammonium persulfate solution was investigated to improve the extraction of metal. The most suitable leaching conditions were determined as follows: matte particle size 96–106 μm, stirring speed 450 rpm, liquid-to-solid ratio 20 mL:1 g, leaching temperature 80 °C, leaching time 4 h, A/M 4.5:1, sulfuric acid concentration 0.25 mol/L, and dropwise speed of adding saturated ammonium persulfate solution 0.48 mL/min. The highest extraction of nickel, copper, cobalt and iron reached 91.8%, 96.1%, 96.6% and 66.9%, respectively.

Preparation of High Nickel Grade Ferronickel From Nickel Sulfide Concentrate with Minimal Sulfur Dioxide Emission

Preparation of High Nickel Grade Ferronickel From Nickel Sulfide Concentrate with Minimal Sulfur Dioxide Emission

Extraction of ferronickel concentrate from laterite nickel ore by reduction roasting-magnetic separation using spent cathode carbon

Laterite nickel ores are the most important raw materials in nickel production, but processing laterite nickel ores with a low nickel content is difficult. Annually, the aluminum electrolysis industry produces a large amount of spent cathode carbon containing toxic substances, such as fluorine and cyanide, but a considerable amount of it cannot be effectively utilized. The purpose of the present study is to prepare ferronickel concentrates by reduction roasting–magnetic separation using spent cathode carbon as a reducing agent. Different factors affecting the agglomeration and growth of metal particles are studied. The migration of fluorine and the aggregation behavior of iron and nickel after the addition of spent cathode carbon and CaO are studied. Results show that the nickel grade in the ferronickel concentrate is 5.4 wt%, the nickel recovery rate is 84.80%, the iron grade is 67.93 wt%, and the iron recovery rate is 89.91%. Efficient recovery and utilization of nickel and iron in laterite nickel ores are realized. Waste utilization of spent cathode carbon thus provides a new method for the treatment of spent cathode carbon.

CLEVELAND-CLIFFS CHROMESHIELD 29 Mo

Abstract Cleveland-Cliffs Chromeshield 29 Mo is a superferritic chromium-molybdenum stainless steel that has outstanding resistance to chloride-induced pitting, crevice corrosion, and stress-corrosion cracking. This grade is dual stabilized with both titanium and niobium to improve weld performance. Cleveland-Cliffs Chromeshield 29 Mo can be an alternative to titanium and high nickel grades. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties. It also includes information on corrosion resistance as well as joining. Filing Code: SS-1356. Producer or source: Cleveland-Cliffs Inc.

The Prospect of Recovering Vanadium, Nickel, and Molybdenum from Stone Coal by Using Combined Beneficiation and Metallurgy Technology Based on Mineralogy Features

Black shale ore contains rich strategic metal resources such as vanadium, nickel, and molybdenum, but due to its complex composition, it is currently only used in the vanadium extraction industry. Metals such as nickel and molybdenum have not been effectively recovered, resulting in environmental pollution and resource waste. Using mineralogical features and a combination of beneficiation and metallurgy-based tests, the present work carried out feasibility studies of the combined beneficiation and metallurgy processes. The mineralogical features of the stone coal sample were studied using chemical analysis, an automatic mineral analyzer (BPMA), etc., and we identified the main phase composition, embedded characteristics, and particle size distribution of the associated strategic metals, vanadium, nickel, and molybdenum. The results showed that the grade of V2O5 in the stone coal was 1.29%, which was mainly present in carbonaceous clay and mica minerals. The nickel grade was 0.53%, mainly in the form of nickel–magnesium spinel and a small amount of nickel-containing magnesite. The stone coal contained 0.11% molybdenum; the mineral particles were fine, mostly in the form of molybdenite, and some were associated with carbonaceous matter and carbonaceous clay minerals. Based on the mineralogical feature, we proposed using the scrubbing–desliming and flotation process to enrich vanadium, nickel, and molybdenum. Our preliminary experiments obtained two products: vanadium–molybdenum-rich sludge and nickel-containing tailings. The V2O5 and molybdenum grades in the sludge were 4.10% and 0.44%, respectively, and the recovery was 41.31% and 51.40%, respectively. The nickel grade in the tailings was 1.49%. These products were roasted and leached. The vanadium, nickel, and molybdenum in the stone coal were effectively recovered through the beneficiation–metallurgy combination process, and the comprehensive utilization rate of the stone coal was improved.

Development of laterite ore processing and its applications

Nickel ore is found in two types sulfide and laterite. The sulfide is a nickel ore that has high nickel content and low reserves of natural resources than of the zinc laterite. In contrast, the laterite is a rock mineral that contains the iron-nickel oxide compounds. There are two methods of processing nickel laterite, namely hydrometallurgy and pyrometallurgy. The former is a method that uses leaching by a chemical solution or solid such as acid, as a reducing agent. The alkaline leaching (ammonia) is the most optimal method to obtain a nickel grade with the highest recovery but it needs more modification. Pyrometallurgical method uses high heat up to 1800°C, so it requires a lot of energy and needs improvement to decrease the carbon usage. The rotary kiln-electric furnace method is the optimal method for developing the nickel laterite. These methods generate products that can be applied to various fields. For example, the pyrometallurgy method produces nickel pig iron and ferronickel as raw materials for stainless steel and steel alloys. The hydrometallurgy method produces nickel sulfate and nickel oxide with a purity of 99% by weight as raw materials for magnets, sensors, and batteries. Hence, the hydrometallurgy method still needs improvements for the environmentally friendly reagent. Therefore, bioleaching will be a nickel laterite leaching process in the future by using bacteria as the reducing agent.

Effects of H<sub>2</sub>O to Reduction Reaction of Low Nickel Grade Oxide Ore

Effects of H<sub>2</sub>O to Reduction Reaction of Low Nickel Grade Oxide Ore