Laterite Ore Research Articles

Mechanism of Directional Reduction Strengthening of Nickel Laterite Ore Under Fluidization Condition

Mechanism of Directional Reduction Strengthening of Nickel Laterite Ore Under Fluidization Condition

Valorization of Solid Residue from the Lateritic Nickel Ore Leaching Process for Ferronickel Production

Valorization of Solid Residue from the Lateritic Nickel Ore Leaching Process for Ferronickel Production

HPAL of a lateritic nickel ore: An investigation on the relationship between nickel and cobalt extraction and acid consumption

Nickel and cobalt raw materials have become essential in industries like batteries such as robotics, and drones, which are considered as future technologies due to their expanding applications and diversity. Research towards the development of environmentally friendly and relatively low-cost alternative methods for extracting nickel, particularly from low-grade deposits, is becoming increasingly crucial. Laterite ores processing is plagued by high reagent consumption and scale formation. This study focused on investigating the relationship between Ni and Co extraction and acid consumption in the high-pressure acid leaching of lateritic ore, as well as the characterization of leach residue. Analysis has shown that the lateritic ore contains 1.05 % Ni, 0.05 % Co and 21.94 % Fe. In the acid leaching tests based upon a Box-Behnken Design, the initial acid concentration and leach time have a beneficial effect on the Ni extraction (70–94 %). Cobalt extractions ranged between 93 % and 96 %. To facilitate Fe dissolution and increase Ni extraction, cuprous ions were added into the leach solution. Moderate level copper addition (0.025 M) resulted in a significant improvement in Ni extraction, whereas high levels of cuprous addition (0.050 M) did not have further benefit. It has been noted that adding cuprous ions significantly reduces the amount of scale that forms in the autoclave. The lowest Ni extraction was obtained under two different test conditions that did not include copper ions. Increased acid addition was correlated with the increase in Ni leaching and decreased Fe content in residue. There will exist an optimal situation where the acid addition is enough to enhance Ni dissolution and the Eh condition, leading to minimal dissolved Fe.

Preliminary Characterisation of Thermal Upgrading of Nickel from Saprolite via Selective Reduction

The mineralogical properties and distribution of information established in saprolite from Indonesia were investigated using X-ray diffraction (XRD), X-ray fluorescence (XRF), scanning electron microscopy energy dispersion spectroscopy (SEM–EDS) and differential thermal analysis (DTA) measurements. The findings suggest that laterite ore has a complex inner core. The percentages of nickel, iron, magnesium, aluminium and silicon in saprolite are 1.82 wt%, 30.47 wt%, 10–20 wt%, 4.86 wt% and 8.1 wt%. Saprolite has 53.1 wt% iron oxide/oxyhydroxide, 38.3 wt% lizardite and 8.7 wt% silicate. According to DTA, saprolite undergoes a phase shift from goethite to haematite at low temperatures (200–300°C). This is a suitable phase to optimise nickel diffusion in iron. Furthermore, the thermal upgrading approach was utilised for this saprolite.

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.

Effect of pH neutral on the separation of nickel and cobalt from laterite leaching solution using cyanex 272

Abstract Nickel and cobalt are the most common elements in the earth’s crust that naturally occur in laterite ores. Nickel and cobalt from laterite ores are recovered as products such as mixed hydroxide precipitate (MHP) and mixed sulphide precipitate (MSP). This research focuses on how the nickel laterite leach solution can be processed directly for solvent extraction without going through the precipitation stage. The nitric acid leach solution obtained from the laterite ore is used to extract nickel and cobalt. A cyanex 272 extractant and kerosene mixture will be used as an organic solvent for direct extraction. The raw material used was Indonesian laterite ore from Halmahera Island, which contained Ni (1.72%), Co (0.155%), Fe (26.17%), and other minor elements. The effect of pH in a neutral condition was investigated on the extraction efficiency, distribution coefficient, and separation factor. Nitric acid (1M) was applied as the leaching reagent. The variables include pH variations (6.8; 7.0; 7.2; 7.4; 7.6), 20% cyanex 272, and O/A ratio (1:1/v:v) at 20 minutes with a stirring speed of 500 rpm. Optimum results were obtained at pH 7.4 variation with an extraction efficiency of 69.26% for cobalt and 0% for Ni, respectively. At these optimum conditions, the highest distribution coefficient value is the element cobalt at pH 7.4, and the result is 2.253 with a separation factor (∞). The optimum condition focuses on removing cobalt from the organic phase, not nickel.

Manufacturing of Fe-Ni Composite Oxide Powder and Leaching Process Optimization Via Nickel Pig Iron(NPI) Raw Materials

The lithium-ion battery industry is experiencing rapid growth in response to the widespread adoption of electric vehicles, leading to a significant increase in demand for high-purity nickel compounds, a critical raw material. As a result, ensuring a smooth supply of nickel resources poses a critical challenge not only for the battery industry but also for enhancing the competitiveness of future clean energy industries. High-purity nickel production is predominantly carried out via the high-pressure acid leach (HPAL) process, which extracts nickel from nickel laterite ores. However, this process involves substantial initial capital investment and consumes significant energy due to high temperatures, high pressure, and strong acids. Additionally, this method is associated with environmental concerns such as water and soil pollution. Furthermore, an alternative approach is proposed, which involves adding sulfur to low-grade nickel pig iron (NPI) to produce the nickel matte, followed by an iron removal process to generate high-purity nickel sulfide. However, this method presents challenges such as waste generation from the iron removal process, high carbon emissions, and the production of large amounts of greenhouse gases. This study explored using anodic oxidation to induce oxidative reactions in NPI to nano-powder. This approach improves nickel recovery efficiency by increasing the surface area compared to the bulk state, allowing leaching at room temperature and atmospheric pressure. As a result, the process becomes simpler, with lower initial capital investment, making it economically viable. Additionally, the process requires less energy consumption, allowing for achieving the breakeven point at an earlier stage. This study compared the characteristics of the nano-powderized NPI under different voltage and current ranges. Furthermore, the nickel leaching efficiency was assessed based on leaching solution conditions.

Bidentate pyridine-pyrazole ligand-induced synergistic and antagonistic effects for selective separation of nickel from sulfuric acid medium

Short-process hydrometallurgy is promising for non-traditional resource utilization due to low cost and less consumption, but it presents a great challenge to metal separation of complex leaching solutions. Herein, a bidentate pyridine-pyrazole ligand (BPP) was synthesized to realize the direct extraction of nickel from sulfuric acid leachate of laterite ore. The separation behaviors of nickel over other impurities (Co, Mn, Mg, Al, Ca, Fe, and Zn) were evaluated for the mixtures of BPP and dinonyl naphthalenesulfonic acid (DNNS). This binary system exhibits the synergistic effect on nickel and antagonistic effect on impurities, which improves the selective separation of nickel. The molar ratio of BPP/DNNS, solution pH, extractant concentration, and nickel concentration on metal extraction were investigated. The extraction efficiency of nickel reaches 95.9 % at pH = 2.5, and the separation coefficients of nickel over aluminum, manganese, and iron is 86.2, 95.4, and 69.4 at the optimal DNNS/BPP molar ratio of 1:1, respectively. Furthermore, the component interaction and coordination structure were disclosed through NMR, ATR-IR, XAS, and UV–vis spectroscopies. The mechanism analysis indicated that the exclusion of coordinated water molecules with BPP contributes to the synergistic extraction of nickel, and the intermolecular interaction between DNNS and BPP inhibits the extraction of impurities. Therefore, the pyridine-pyrazole ligand-induced synergistic and antagonistic effects will be helpful to the short process utilization of complex nickel-bearing resources.

Research of Reactions on Ferronickel Laterite by Rotary Kiln Furnace Process

Nickel is an important strategic metal, which is mainly used for the production of a wide range in the production of various anti-corrosion steels. Electric furnace, rotary kiln and smelting is currently the world-wide integration process for the production of ferronickel from nickel laterite ore, despite its high energy consumption. In this study, with the aim of providing some meaningful analysis for the production of ferronickel and reactions formed in the rotary kiln. The samples obtained were analyzed under conditions including reducing parameters (temperature and time) and smelting parameters (CaO, Al2O3 and MgO ratios). The metal content as well as the Ni, Fe, S and P content of ferronickel were taken into account. The results showed that Ni-containing ferronickel from a laterite with 0.88 wt. % Ni during the process in the rotating furnace is characterized by different reactions which have been verified by XRD diffraction.

Characterization and Beneficiation of Fanibi Laterite for Nickel Metal Recovery Using Froth Flotation Method

This study investigates the characterization of Fanibi Laterite and the efficiency of froth flotation to beneficiate nickel from its host rock sourced in Akure, Ondo State, Nigeria. A sample of the laterite was obtained and characterized by the use of an X-ray fluorescence Spectrometer (XRFS), X-ray diffractometer (XRD), and Scanning electron microscope with Energy dispersive spectroscope (SEM/EDS). The ore was comminuted to its liberation size of -125 + 90 µm. The froth flotation process was done using Sodium hydroxide and Hydrogen tetraoxosulphate (VI) acid as hydrogen potential (pH) modifier within the range of 4,5,7,9 and 10. However, other reagents are sodium oleate as the collector, potassium dichromate as the depressant, and oleic acid as the frother. The froth and depressed obtained were dewatered and characterized using XRFS. The result revealed that the ore contained 35.65% Si, 8.24% Al, 10.87% Fe, and 0.07% Nickel. It also included some other associated minerals such as Zn, Mg, Ti, Co, and Mo in trace form of less than 1 %. XRD analysis reveals nickel as nickel iodate. The result reveals nickel assays of 0.14, 0.20, 0.15, 0.25, and 0.12%, while their recoveries are 70.82, 67.80, 86.70, 98.04, and 86.98%, respectively. The optimum nickel recovery of 98.04% was attained at a pH of nine (9). It was concluded that froth flotation could successfully beneficiate Fanibi laterite ore for nickel. At the same time, other minerals such as Titanium, Molybdenum, Tin, and Tungsten were present to be extracted for Metallurgical applications.

Sulfur Removal and Iron Recovery from High-Pressure Acid Leaching Residue of Nickel Laterite Ore

Sulfur Removal and Iron Recovery from High-Pressure Acid Leaching Residue of Nickel Laterite Ore

Study on the treatment of pyrolysis products from the nitric acid pressure leach liquor of laterite

As the demand for nickel increases sharply, it is of great significance to extract valuable metals such as nickel and cobalt from lateritic nickel ore with huge reserves. Based on the nitric acid pressure leaching process (NAPL) of laterite nickel ore, a clean process of laterite nickel ore treatment is proposed. The process includes concentration and crystallization of pressure leaching solution of nitric acid, pyrolysis of mixed nitrate crystal, alkaline leaching of mixed oxides and acid leaching of alkaline leaching residue. Based on previous work, the high-pressure alkaline leaching process of pyrolysis products (mixed oxides) and atmospheric pressure sulfuric acid leaching process of alkaline leaching residue were studied in this paper. First, the Eh-pH diagrams of metal-water system of common elements in laterite nickel ore was summarized according to the reaction equations of different substances in aqueous solution, and the subsequent wet leaching process was guided. The following alkaline leaching experiments showed that under the conditions of 300 g/L NaOH concentration, 3.5 mL/g liquid–solid ratio, 160 °C leaching temperature and 1 h leaching temperature, 85.0 % of aluminum in mixed oxides can be leached and scandium can be enriched by 13 times. Finally, under the conditions of initial sulfuric acid concentration of 4 M, temperature of 100 °C, leaching time of 30 min and liquid–solid ratio of 4 mL/g, the leaching rates of Al, Ni, Mg, Co, Mn, Fe and Sc in alkaline leaching residue were 92.0 %, 97.5 %, 98.4 %, 92.3 %, 62.7 % and 68, respectively. A new procedure for treating lateritic nickel ore is proposed, allowing for thorough recovery and usage of important components. The technique is green and environmentally benign, resulting in closed-loop production of laterite-nickel ore treatment with numerous application possibilities.

Recovery of Pure Co(II) and Ni(II) Solutions from Synthetic Sulfate Leach Liquor of Laterite Ores by Precipitation and Solvent Extraction

ABSTRACT Recovery of nickel and cobalt from laterite ores is important to meet the demand for these metals. In this work, a process was developed for the separation of metal ions from synthetic sulfate leach liquor of laterite ores containing Fe(III), Al(III), Ni(II), Co(II), Ca(II), Mg(II), and Mn(II). First, Fe(III) and Al(III) were removed by precipitation of their hydroxides by adjusting solution pH and then Mn(II) was removed from the filtrate by oxidative precipitation with NaClO. Sequentially, Co(II) and Ni(II) from the filtrate containing Mg(II) and Ca(II) were separated by selective precipitation of CoS and NiS by adding Na2S solution, leaving Ca(II) and Mg(II) in the filtrate. The mixed precipitates of CoS and NiS were completely dissolved by 0.1 M HCl solution containing NaClO. Co(II) can be separated from Ni(II) present in the HCl solution by either oxidative precipitation with NaClO or selective extraction with saponified Cyanex 272. Optimum conditions for these procedures were obtained. Continuous experiments indicated that the purity of Co(II) and Ni(II) solutions was higher than 99%.

Briquette Shape Roles in Carbothermal Reduction Process of Limonitic Laterite Nickel

Lateritic ore carbothermalreduction is currently the focus of many researchers. This process uses a relatively lower temperature of operation than the smelting. Therefore, the carbothermal reduction process has a relatively lower primary energy demand and CO2 gas emissions. This research examines the appropriate briquette form to obtain the optimum recovery, concentration of nickel, and selective reduction of nickel, as well as analyzes the compounds/phases formed. The briquette in this study was formed into three different geometries, i.e., the pillow, spherical, and cylindrical forms. First, this research was carried out by mixing the raw materials and forming it into specified briquette forms. Second, the formed briquettes were put into a crucible. Third, the coal-limestone bed mixture was used to cover the briquettes. Then, the carbothermic reduction process was started by heating to 700 oC for 2 hours and continued to 1400 oC for 6 hours. Finally, the magnetic separation process was performed to separate the reduced briquettes. As a result, the cylindrical shape briquette obtained better results at 6.74% Ni, with a nickel recovery of 96.20% and a selectivity factor value of 10.39. The compounds formed after carbothermic reduction process products include FeNi, Fe3Si, and SiO2. In a spherical-shaped briquette, Fe3O4 and Mg2SiO4were found in the reduced product, indicating impurities in the reduced briquettes.

Rapid iron extraction from nickel leaching residue by a hydrogen plasma smelting reduction

The processing of limonite-type lateritic nickel ore through sulfuric acid leaching generates leaching residue that requires careful handling and treatment. This residue, which contains over 38% iron, has the potential to be an alternative raw material for the iron and steel industry. However, the direct use of this residue as a burden material in the steel industry faces challenges due to the substantial presence of sulfur, which exceeds 1%. In the pursuit of sustainability within the iron and steel sector, researchers have increasingly focused on advancing hydrogen plasma technology. Laboratory tests were conducted on the treatment of the leaching residue exposed to hydrogen plasma smelting reduction. The results revealed that within just 5 s of exposure to hydrogen plasma, the transformation of the residue into metal was initiated. After 30 s of exposure, the formation of metal had already occurred, but the sulfur content remained above 0.5%. However, when the residue was exposed to hydrogen plasma for 180 s, the sulfur content in the metal decreased to less than 0.1%. The presence of nickel and chromium in the resulting metal products should be taken into consideration, especially when special steels or stainless steel are being produced.

From source to sink via a ferronickel smelting process: Chromium, nickel, and mercury in sediments of the Evoikos Gulf, Greece

Ferronickel smelters are highly waste intensive industrial processes. In the Larymna Bay (LB) of the Evoikos Gulf (Greece), the slag produced after the processing of lateritic ores for nickel extraction used to be discharged to an authorized marine area (slag disposal area; SDA). This study assessed the distribution of Cr, Ni, Fe and Mn, largely related to ultramafic parent rocks, laterites, and the slag, as well as Hg as a tracer of combustion processes in the sediments of Evoikos Gulf. A very severe (Cr) and moderate (Ni) enrichment was found both in LB and SDA in relation to local background levels. Mercury was severely enriched in LB. LB becomes enriched with magnetic particles and metals through washout and deposition of dust. Magnetic susceptibility was found to be a good proxy for Cr and Ni distributions, as well as the dispersal of slag because both parent rocks and slag contain magnetite-like magnetic minerals. The strong tidal currents of the area do not cause the dispersal of slag particles southwards, beyond SDA, yet they are responsible for the accumulation and focusing of Hg in the South Evoikos Gulf, close to the Chalkida city. Metals mobilization potential from the slag was higher compared to laterites, but lower compared to SDA's sediments, due to reduction processes in the plant and oxidation after its disposal, respectively. Oxidation processes result in the genesis of Cr(VI) in SDA and LB, through oxidative reactions with Mn oxides. This is the first time (to the best of our knowledge) that the formation of Cr(VI) from slags is reported. This finding is important for settings rich in Mn oxides, receiving Cr-rich wastes from Fe–Ni smelter plants.

Collaborative extraction of valuable components from saprolitic laterite ore through two-stage nitric acid leaching

Saprolitic laterite ore (SLO) is an important Ni resource that also contains high Mg and a small amount of Sc, but traditional extraction techniques cannot achieve the comprehensive utilization of valuable components, especially Mg and Sc. In this work, a new process was proposed to treat SLO through the application of an HNO3 medium. First, E-pH analysis showed that serpentine and part of iron oxide are easily destroyed, and Ni and Co embedded in silicate and Fe-bearing minerals can be also leached. Subsequently, Ni, Mg, Co, and Sc can be efficiently extracted under the HNO3 concentration of 240 g/L, 90 ℃, L/S of 5:1, 2 h, and 200 r/min. Relevant characterization confirmed that serpentine and goethite were almost completely dissolved after leaching. However, magnetite and its alteration intermediates have relatively stable properties and cannot be destroyed. To reduce acid consumption, the leach liquor was supplemented with HNO3 for two-stage leaching. Efficient extraction of valuable metals can be achieved again with the supplemented HNO3 concentration of 192 g/L. A two-stage leaching process can save 120 kg HNO3/t-ore. Finally, a technical route including two-stage HNO3 leaching, adding MgO to adjust pH, and pyrolysis of Mg(NO3)2 to regenerate HNO3 and MgO was suggested.

Do ferrous iron-oxidizing acidophiles (Leptospirillum spp.) disturb aerobic bioleaching of laterite ores by sulfur-oxidizing acidophiles (Acidithiobacillus spp.)?

The extraction of nickel, cobalt, and other metals from laterite ores via bioleaching with sulfur-oxidizing and ferric iron-reducing, autotrophic, acidophilic bacteria (e.g. Acidithiobacillus species) has been demonstrated under anaerobic as well as aerobic conditions in experiments in different laboratories. This study demonstrated the bioleaching of laterites from Brazil with the addition of elemental sulfur in 2-L stirred-tank bioreactors with pure and mixed cultures of Acidithiobacillus and Sulfobacillus species under aerobic conditions. In particular, a potential disturbance of mineral dissolution under aerobic conditions by ferrous iron-oxidizing acidophiles likely introduced as contaminants in an applied bioleaching process was investigated with Leptospirillum ferrooxidans at 30°C and Leptospirillum ferriphilum at 40°C, at maintained pH 1.5 or without maintained pH leading to an increase in acidity (with pH values <1.0) due to the biological production of sulfuric acid. Despite the proportion of ferrous iron to the total amount of extracted iron in the solution being drastically reduced in the presence of Leptospirillum species, there was a negligible effect on the extraction efficiency of nickel and cobalt, which is positive news for laterite bioleaching under aerobic conditions.

Nickel recovery in tailling from the Chromite beneficiation process in Mau Lam, Thanh Hoa by the reduction roasting-magnetic separation process

In Thanh Hoa province, large chromite ore deposits were discovered. These types of ores also contain significant quantity of nickel metal, with total nickel reserves estimated to be over three million tones. According to the practices of mining and beneficiation of these chromite ores, nickel is discarded in the waste dumps as a non-valuable metal and has not been recovered ever. Through many years of mining and processing of chromite ores, large dumps are formed to such huge volumes that can be considered as a significantly secondary resource of valuable nickel metal. Nickel exists in the form of laterite ores so that it is difficult to be recovered. Currently, there is no commercial technology available for recovery of nickel or other valuable metals from this type of raw material sources. This article presents some research results on applying the reduction calcination – magnetic separation process for recovery of nickel. In particular, some important reduction operating variables such as temperature, calcination time, fuel coal ratio, and Na2SO4 additive were investigated. From the tailing samples of the Mau Lam – Thanh Hoa chromite beneficiation process, important optimal reducing conditions have been determined including 1,1000C of reduction temperature, 8% of anthracite coal, 8% of Na2SO4 additive, and the reduction time of 90 minutes. The reduced product was finely grounded and separated at a magnetic field of 0.3T using the wet magnetic separator. At optimal operating variables, the nickel content of the final nickel concentrate was 4.02% Ni and the overall nickel recovery was 91.2%. The positive results necessarily lead to a need to continue researching the possibility of practical application to recover nickel and thus contribute to the rational utilization of mineral resources of the country.

Selective removal of Fe(Ⅲ) from HNO3 leach liquor of saprolitic laterite ore: Precipitation efficiency, hydrolysis mechanism, and removal strategy

HNO3 leach liquor of saprolitic laterite ore contains Fe3+, Al3+, Sc3+, Ni2+, Co2+, Mg2+, etc. Efficient removal of Fe3+ while reducing the loss of valuable metals is the key to solution purification. In this paper, a detailed study was carried out on the removal of Fe3+ by hydrolysis precipitation. First, thermodynamic calculations were conducted to analyze the precipitation pH changes and possible hydrolysis products at different temperatures. Subsequently, the experimental results show that more than 99 % Fe can be removed via low-temperature hydrolysis at 25–80 ℃ and pH = 3.0–3.5, but over 40 % Al and 30 % Sc also precipitate together, causing valuable metals losses. Differently, under high-temperature conditions (180 ℃, pH = 1.0, 0.5 h), 99.49 % of Fe can be selectively removed as Fe2O3 product, while other valuable metals hardly precipitate. It was found that the low-temperature Fe removal residue exhibits irregular agglomeration and uneven particle size, and contains 9.48 % NO3– and 25.86 % Fe. The high-temperature Fe removal residue presents a nanoscale spherical shape with uniform particle size and only contains 0.087 % NO3–, and the Fe content is up to 69.07 %. Finally, the Fe3+ hydrolysis mechanism was analyzed and an efficient Fe removal process from the HNO3 system including pH adjustment of leach liquor, selective Fe removal at high temperature, flash evaporation to recover free HNO3, and solid–liquid separation to obtain Fe2O3 products was proposed.