Nickel Laterite 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.

Mineralogy and Geochemical Characteristics of Lateritic Nickel Deposit in Wiwirano District, North Konawe, SE Sulawesi, Indonesia

This research aims to understand the mineralogical and geochemical characteristics of the nickel laterite deposit in the East Sulawesi Ophiolite Belt in Wiwirano District, North Konawe, Southeast Sulawesi, Indonesia. The deposit is analyzed and described to determine the laterization process and supergene enrichment. The geochemical data was obtained from X-ray fluorescence analysis, and mineralogical data from petrography and X-ray diffraction analysis. The minerals in the limonite zone are dominated by goethite and hematite. Minerals found in the saprolite zone include quartz, orthopyroxene, and lizardite, whereas the bedrock is made up of olivine, orthopyroxene, serpentine, and chromite. Fe2O3, Al2O3, and Co contents are high in the limonite zone, SiO2 and MgO have high content in the saprolite zone, and Ni is enriched in the saprolite zone. The distribution of enriched Ni is controlled by bedrock or parent lithology with an average content of 1.3% - 2.4% in saprolite, while in the limonite zone, Ni content is lower with an average content of 0.8% - 1.2%.

Study on leaching SiO2 and kinetics of laterite nickel ore in hydrometallurgy

Study on leaching SiO2 and kinetics of laterite nickel ore in hydrometallurgy

Preparation of Nickel–Iron Concentrate from Low-Grade Laterite Nickel Ore by Solid-State Metalized Reduction and Magnetic Separation

Preparation of Nickel–Iron Concentrate from Low-Grade Laterite Nickel Ore by Solid-State Metalized Reduction and Magnetic Separation

Recovery of ferronickel by green selective reduction of nickel laterite

Abstract The conversion of nickel laterite into ferronickel is commonly done through a high-temperature pyrometallurgical process that utilizes fossil fuels, which leads to environmental emissions. In order to deal with this, a biomass-based selective reduction process is proposed that uses palm shell charcoal (PSC) as the reductant. In this study, we investigate how to selectively reduce saprolytic nickel ore in various conditions, including pelletization, reduction at 1150°C for one hour, and wet magnetic separation. The optimal conditions, determined with 0.3 stoichiometric carbon, yielded a nickel content and recovery of 22.778 wt.% and 27.541 wt.%, respectively. Phases identified in the reduced pellet include forsterite, diopside, ferronickel, troilite, and olivine. Adjusting stoichiometry influences nickel concentration, resulting in increased recovery; however, excessive stoichiometry intensifies iron metallization, reducing nickel content. The addition of sodium sulfate affects nickel and iron recovery by promoting FeS phase formation, resulting in reduced iron recovery.

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.

Migration of dissolution front in a fracture network − Implications for weathering of fractured bedrock systems and boulder formation

Fracture networks contribute to the differential weathering of fractured bedrock at multiple scales. The influence of competing fracture networks is discussed in light of hydrogeochemical conditions to predict the dissolution pattern resulting from spheroidal weathering. The investigation of the dimensionless Péclet (Pe) and Damköhler (Da) numbers on a simple case of a dual-scale fracture network and its application to three fracture network weathering reveals the influence of fluid flow and reaction rate conditions on the dissolution patterns.The conceptual model was numerically validated and compared with observations on lateritic nickel deposits in New Caledonia. A fracture network will contribute to boulder development if the associated fluid flow regime reaches a Pe threshold of around 10. On the other hand, predominant diffusion will inhibit the fracture set in favour of a higher permeability fracture network. The Da drives, for its part, the width of the dissolution halo. Owing to the dependency of the fluid flow regime on the fracture network characteristics, scaling laws were established to estimate the size of the boulders at different scales by predicting the fracture contribution as a function of their Pe.

Analysis of Cobalt Distribution and Co-Ni Correlation in Nickel Laterite Zonation in Tropical Region

Cobalt is a key metallic element required in the manufacture of lithium-ion batteries in the electric car industry, which has led to increased demand for cobalt globally. Cobalt is found associated with laterite nickel deposits but generally at lower levels. This study aims to analyze the distribution of cobalt in the laterite zone, determine cobalt-rich zones, determine cobalt-forming minerals in the limonite, saprolite and bedrock zones. As well as determining the average cobalt content in each nickel laterite zone, and determining the correlation between Co and Ni in the laterite zone. The research methodology was carried out by conducting petrographic analysis on bedrock samples to determine cobalt-forming minerals. Furthermore, X-Ray Diffraction analysis was carried out on limonite and saprolite zone samples to determine the mineral content and cobalt-forming minerals. Furthermore, conduct X-Ray Fluorescence analysis at 12 drill points to determine the percentage of cobalt elements in each laterite zone. Based on the research results, it is known that the distribution of cobalt at 12 drill points has levels in the limonite zone ranging from 0.05-0.12% Co, saprolite zone 0.02-0.05% Co, and the bedrock zone ranges from 0.01-0.04% Co. So it can be concluded that the highest cobalt distribution is in the limonite zone and the average cobalt content in the limonite zone is 0.082%; saprolite zone is 0.029%; and bedrock zone is 0.02%. The mineral identified as the cobalt-forming mineral in the bedrock samples in the study area is the mineral antigorite. The Co-Ni correlation coefficient values range from 0.01 to 0.22.

Nickel recovery in ferronickel concentrate by green selective reduction of nickel laterite

Nickel laterite is typically processed into ferronickel through a pyrometallurgical method involving high temperatures and the use of fossil fuels, such as coals or cokes. Unfortunately, this process releases emissions like CO2, SO2, and NOx into the environment. This study explores a sustainable approach for nickel laterite processing by investigating low-temperature selective reduction using various biomass reductants. The materials, including saprolitic nickel ore and biomass types (palm kernel shell charcoal or PSC, lamtoro wood charcoal, coconut shell charcoal, and rubber wood charcoal), undergo pelletization, selective reduction at 1150 °C, and wet magnetic separation. PSC biomass is superior to other biomass due to its 217.2 m2/g specific surface area value. Optimal conditions were achieved using 0.3 stoichiometric PSC, along with the addition of 10 wt% of sodium sulfate as an additive. This has led to a nickel mass fraction of 26.0 wt% and a recovery rate of 27.4 %.

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.

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.

Co, Sc, and Ni enrichment in the Cagdianao nickel laterite deposit, Dinagat Islands, Philippines

Abstract Nickel laterites are soils that are derived from the weathering of mafic and ultramafic rocks. These deposits are being extracted mostly for their economic Ni and Fe content. However, in recent studies, the potential of nickel laterites to hold significant amounts of critical metals such as Sc and Co are already being investigated. In the Philippines, nickel laterite deposits form through the weathering of ophiolitic units. One of these is the Cagdianao nickel laterite deposit which was derived from the weathering of the ultramafic units of the Dinagat Ophiolite Complex in Dinagat Island, Surigao Del Norte, Philippines. The bedrock of the Dinagat Ophiolite Complex is dominantly comprised of harzburgite. This harzburgite bedrock is overlain by a nickel laterite profile consisting of horizons of Mg- and Si-rich rocky saprolite, earthy saprolite, Fe-rich limonite, and an Al-rich topsoil. Drillcores and field exposures of the nickel laterite profile were observed, sampled, and subjected to petrography, whole rock geochemistry (XRF and ICPMS), and mineral chemistry (LA-ICPMS) analyses. In terms of major elements, Fe is dominant in the limonite zone (up to 59.76 wt.%). Mg and Si are more enriched in the rocky saprolite layer (up to 28.41 and 37.41 wt.%, respectively). In terms of the critical minerals, Ni is more enriched in the saprolite zone (up to 29936 ppm) while Co and Sc are more enriched in the limonite zone (up to 1080 and 86 ppm, respectively). Elemental mapping of the bedrock samples reveals the strong affinity of Ni to olivine and serpentine. Sc was revealed to have a greater affinity with orthopyroxenes. Lastly, Co is observed to have a slight affinity with olivine. These results show a relative enrichment of Co in the profile, particularly in the limonite. Co within the laterite profile also has a very strong affinity with MnO. Similarly, the highest concentration values for Sc were also observed in the limonite. It also exhibits an affinity for Fe2O3 and Al2O3. Lastly, Ni was observed to have a strong affinity with olivine and serpentine minerals in the bedrock and the rocky saprolite horizons. Within the deposit, Ni is the main commodity while Co, Sc, and REEs can be considered as by-products.

Geostatistical Models and Estimation of Laterite Nickel Ore Reserves, Marombo Block, South Sulawesi

Abstract Geostatistical modeling in this study requires a distribution of drill points that have a fixed dimension so that they can produce a reserve accuracy match that is the same as the variograph. The choice of reserve estimation method is prioritized by determining the geological domains of limonite, saprolite and bedrock through a geostatistical approach, namely ordinary krigging (OK) and inverse distance weight (IDW) with the JORC standard (2012), for the accuracy of the limonite and saprolite zone boundaries. The reserve model has shown a definite model of the limonite and saprolite zones and can be used further. By using simulations on cut-off grade (COG) to calculate resources and classify mineral resources, the estimation results obtained mean nickel levels above 1.40% so that the CoG to be used must be greater than Ni 0.90% for limonite, and Ni 1.10% for saprolite. The results of modeling the geometry of laterite nickel ore obtained that the total tonnage shown in limonite was 0.36 wmt (wet metric ton), inferred 0.10 wmt, and indicated in saprolite was 0.58 wmt, inferred was 0.40 wmt.

Using Soil Magnetic Susceptibility Proxies to Estimate Overburden Thickness Overlying Ore of Lateritic Soils in Sulawesi Island Indonesia

Sulawesi Island is one of the largest Ni ore producers in Indonesia. It is also expected to be a significant potential source of some critical metals (e.g., Co, Sc, rare-earth elements, and platinum-group elements). However, few studies show the post-mining impact on some heavy metal elements concentrated in this area. Therefore, improving the efficiency and effectiveness of soil organization and its effect on soil reclamation after mining is helpful. This study aimed to determine the accuracy in estimating the thickness of the overburden covering the nickel ore body profile from lateritic nickel post-mining areas by magnetic susceptibility measurements to discrepancy the overall laterite horizon, whereas χLF and χFD are used to distinguish the overburden zona and limonite and saprolite zone. The lateritic profile studied consists of soil formation of Fe-rich material in the Morowali, and Pomalaa block. We also evaluated the chemical element content of the soil and understood the relationship between the magnetic and geochemical properties of the soil. This study reveals the superparamagnetic (SP)-enriched soils indicated with the increase of the FD% values into the upward horizon, where the maximum values of FD are generally found at ranges 1 to 4m, indicating the overburden layers. Meanwhile, in the depth of 4m to 6m, the values of FD vary only slightly in the lower part initiated by the limonite layers, and then > 6m decreases sharply to the bottom, indicating the saprolite layers. The chemical element mobility trends indicate that Fe, Co, Cr, Mn, and Ti increase toward the layers, which is the same pattern as in FD. Due to this, parameters magnetics may also be a new geophysical approach for estimating the distribution of economically valued minerals on lateritic soils. The strong correlation of Co with Fe, Mn, and Cr in all layers indicates the influence of weathering o n these ultramafic rocks. This suggests an increasing trend toward prolonged pedogenesis.

Recovery of high-quality iron phosphate from acid-leaching tailings of laterite nickel ore

Laterite nickel ore is rich in nickel and iron resources, and the nickel element is extracted in the form of nickel salt. However, the acid-leaching tailings of laterite nickel ore (LTLNO), which contain valuable iron resources, have not been cost-effectively recovered. In this work, we designed a novel method to extract iron from LTLNO and recycle it into high-valuable iron phosphate products using only phosphoric acid and iron powder. We explored the effects of reaction parameters, such as phosphoric acid concentration, iron powder dosage, time, and temperature, on the leaching behavior of key elements. The results showed that the iron leaching rate was as high as 96.54 % when using 3.5 mol/L phosphoric acid with a liquid-to-solid ratio (L/S) of 5 mL/g and an iron powder dosage based on the Fe/Fen+ ratio of 0.5 after 3 h at 25 °C, and a final high-purity FePO4 (99.4 %) was obtained. Kinetic analysis revealed that the leaching reaction was controlled by the diffusion through the neogenetic layer, and the leaching reactions were thermodynamically favorable. This method allows for a simpler and more efficient recovery of iron and the products of higher-value iron phosphate products than other LTLNO recycling technologies. Additionally, it offers a total economic benefit of $134/t for LTLNO treatment, demonstrating great prospects for industrial application.

Nickel, chromium, and cobalt in soils developed on nickel laterites near an abandoned mining area in southern Czech Republic

Geochemical anomalies are gaining importance due to the Europe's renewed prospecting activities for technologically critical metals, such as nickel (Ni) and cobalt (Co). In this context, soils developed on Ni laterites near old open pit mining and exploration works near Křemže in southern Czech Republic were investigated using multi-method approach to assess the distribution, solid speciation, and (bio)availability of the trace metals, with a particular focus on Ni, chromium (Cr), and Co. The total concentrations of metals in the studied soils (Ni: 170–4950 mg/kg, Cr: 56–1190 mg/kg, Co: 14–424 mg/kg) exceeded the median world regulatory guideline values (Ni: 112 mg/kg; Cr: 250 mg/kg; Co: 50 mg/kg) as well as the Czech concentration limits for agricultural soils for most of the samples. The concentration of metals in the soil profiles generally increased as a function of depth with surface horizons in agricultural plots homogenized by ploughing. The effect of a former open pit mine (already closed for ca 80 years) on the vertical distribution of metallic elements has not been demonstrated. The extractable metals were relatively low (extraction efficiency order: water < DTPA < EDTA). The mean EDTA-extractable values corresponded to 4.2 % Nitot, 8.6 % Cotot, and only 0.14 % Crtot. This contrasting metal availability is strictly related to the metal speciation in the solid phase. The primary minerals (olivine, clinopyroxene) are highly weathered to secondary phyllosilicates (lizardite, talc) and Fe oxyhydroxides and Mn oxides, all representing important carriers for Ni. Cobalt was exclusively hosted by Mn oxides, and the less mobile Cr was mainly bound in insoluble phases, likely spinel-family oxides. Despite the relatively low metal availability, elevated concentrations of Ni in the crop biomass (86 mg/kg) collected in the agricultural area suggest a metal uptake from the soil, which should be further investigated in detail.

Waste to treasure: A sustainable technic to prepare high-performance lithium iron phosphate from laterite nickel tailings

The abundance of laterite nickel tailings after nickel extraction not only generate severe environmental contamination but also result in significant waste of metal resources, particularly iron (Fe). Herein, a promising technic of recycling tailings to high-value Fe-based energy storage materials is developed to address above challenges. The traditional hydrometallurgy is firstly applied to leach Fe source from laterite nickel tailings. By referencing the Eh-pH thermodynamic stability phase diagram of the phosphorus system, Fe could be preferentially precipitated in various metal elements, enabling the effective extraction of Fe as raw iron phosphate (FePO4). Notably, a two-step purification strategy is designed to remove residual impurity and adjust Fe/P ratio, subsequently obtaining the high-purity battery-grade FePO4. Finally, a solid-phase method is conducted to prepare nano lithium iron phosphate (LiFePO4) with outstanding electrochemical performance (1C > 150 mAh/g), meeting rigorous commercial standards. Economic analysis further confirms the significant value of implementing this scalable recycling technic, and the potential industrial application is highly anticipated. Thus, this research proposes a sustainable tailings recovery methodology, offering valuable insights for the recycling of other Fe-containing resources.

Sulfuric acid leaching of ferronickel and preparation of precursor materials for power batteries: Strategy of enhanced leaching through thermal activation and its mechanism

With the development of the new energy industry, the demand for iron phosphate and nickel–cobalt hydroxide precursor materials in the power battery industry has increased sharply. Ferronickel with low content of other impurities, derived from electric furnace smelting of laterite nickel ore, contains iron, nickel, and cobalt components used for the production of two kinds of power batteries. In this study, the sulfuric acid leaching behaviors of the water quenched ferronickel particles under atmospheric pressure was investigated. Practically, the direct leaching performance of these ferronickel particles in sulfuric acid is unsatisfactory. The leaching of Ni, Co and Fe was only 4.52 %, 3.58 % and 3.83 %, respectively, at the initial acid concentration of 3 mol/L, liquid–solid ratio of 12 mL/g, leaching temperature of 95 °C and time of 4 h. However, through thermal activation, the face-centered cubic (FCC) Fe-Ni phase was transformed into the body-centered cubic (BCC) structure, which significantly improved its acidic leaching activity. Under the thermal activation at 800 °C for 2 h, the leaching of Ni, Co and Fe reached 91.27 %, 90.12 % and 89.19 %, respectively, at the same leaching conditions. After oxidizing the Fe(II) in lixivium to Fe(III) using hydrogen peroxide, 89.3 % of Fe was selectively precipitated into battery-grade iron phosphate by adding phosphoric acid and coordinating solution pH. Nickel and cobalt in residual solution was then recovered to nickel–cobalt hydroxide by precipitation after removing impurity ions in advance. This study provides a new pathway for the value-added utilization of ferronickel in the power battery industry, not only in the production of stainless steel.