nickel laterite industry with a focus on hydrometallurgy ...hydromet.no/presentasjoner/lillestrøm...
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Hydromet‐seminar at IFE, March‐2017The Nickel Laterite Industry with a Focus on Hydrometallurgy
Ole Morten Dotterud, Glencore Nikkelverk AS
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Nickel industry in perspective…
• Natural resource‐industries (peak production in mln tonnes per year):– Coal: 8 200– Limestone: 5 000– Crude Oil: 4 000– Natural Gas: 2 600– Grains: 2 500– Iron ore: 2 300– Steel: 1 700– S/S‐equiv.: 70– Al: 60– Cu: 20– Zn: 13– Pb: 4.7– Ni: 2.0– Co: 0.1
But the price picture is inverse, Ni is ~200 times more expensive than coal…
China consumes ~40‐50% of many of thesecommodities, exceptgrains, crude oil, naturalgas and S/H2SO4.
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Global nickel laterite resources(Source, G.W.Bacon, Inco 2004)
Global Nickel Resources 230 Mt Contained Nickel
Laterite Resources by Region 161 Mt Contained Nickel
New Caledonia
Indonesia
PhilippinesBrazil
Cuba
Australia
Africa
AmericasOther
Laterite70%
Sulphide30%
R/P = 230/2.3 ~ 100 yrs Apparantly no lack of resources…
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Distribution of global nickel resources
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Typical profile for laterite ore, applicable technology
”Peridotite” = Mineralclass (Xa,Yb)SiO4, or XO(Yc,Zd)SiO4, example. olivine, X=Mg
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Illustrated with concentration profiles
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Laterite Nickel Production ‐Principal Technologies
Fron
t end
Bac
k en
d
PyroHydro
NPI,
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Disadvantage for laterites vs. sulphidenickel ores• A sulphide ore can usually easily be upgraded in Ni‐concentration
through a combination of comminution methods, like• Grinding• Milling• Classification• Flotation• Magnetic separation• And similar methods
• Ni‐sulphide ores usually contain between 0.5 – 3% Ni• “Ni‐concentrates” (from upgrading) normally contain between 5 – 20% Ni• An concentration ratio of 5‐10 times is obtained.
• Not so with lateritic nickel ores, particularly the limonite type• Typical grades in commercial mining operations:
• Limonite: 1.0 ‐ 1.7% Ni• Saprolite: 1.5 ‐ 3% Ni
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HPAL principal flowsheet for Limonite oresFront end (up to intermediate/concentrate)
Intermediate options:
MSP:• Mixed Sulphide Precipitation• Use H2S(g), low pressure
MHP:• Mixed Hydroxide Precipitation• Use "activated" MgO
Direct SX:• One example ‐ Cyanex301• Other example –
DEHPA+Versatic10 (not in oper.)
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HPAL Flowsheet, Main chemistryAcid leaching• Solubilize Ni and Co• Keep Fe, Al (and some other elements) in residue• Reach low free acid concentration in solution
Ni and Co:• MeO + H2SO4 = MeSO4 + H2O, Me = Ni, Co
Fe:• Step 1: 2FeO(OH) + 3H2SO4 = Fe2(SO4)3 + 4H2O• Step 2: 2Fe(SO4)3 + 3H2O = Fe2O3 + 3H2SO4• Net: 2FeO(OH) = Fe2O3 + H2O• Fe may also form some FexOy(SO4)z, basic sulphates
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HPAL Flowsheet, Main chemistryIntermediate precipitation• Remove dissolved Ni and Co from pregnant leach solution• In a form acceptable to a refinery
• Both chemically (like impurity content) and physically
Mixed Sulphide Precipitation (MSP):• MeSO4 + H2S(g) = MeS(s) + H2SO4, Me = Ni, Co, others
Mixed Hydroxide Precipitation (MHP):• MeSO4 + MgO(s) = Me(OH)2(s) + MgSO4, Me = Ni, Co, others
Comments:• MSP:
– Technically more challenging– Better acceptance of MSP vs. MHP, can easily be fed into Ni‐matte
refineries
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Caron principal flowsheet for Limonite ores
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Caron Flowsheet, Main chemistry1. Reducing roast• Selectively metallize Ni and Co• Partial reduction of iron to magnetite • A small amount of iron is also metallized• Metallic phase is a Ni‐Fe‐Co alloy, Ni/Fe ratio ½
• 3 Fe2O3 + CO = 2 Fe3O4 + CO2
• NiO + CO = Ni + CO2
• Fe3O4 + CO = 3 Fe + CO2
• CoO + CO = Co + CO2
• Fe3O4 + CO = FeO + CO2
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Caron Flowsheet, Main chemistryNi and Co solubility in NH3‐solutions
Ni-NH3-H2O system: [Ni] = 1 M, [N] = 1M Co-NH3-CO3-H2O System
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Caron Flowsheet, Main chemistryOxidative leach and complex ion formation
• Subreactions:• M = M2+ + 2 e‐• M2+ + 6 NH3 = M(NH3)62+• Co(NH3)62+ = Co(NH3)63+ + e‐• Role of Oxygen:
– O2 + 2 H2O + 4 e‐ = 4 OH‐
• Buffersystem NH3‐CO2:• NH3(g) + CO2(g) + H2O = (NH4)2CO3 = 2NH4
+ + CO32‐.
• 120 g/l NH3 + 100 g/l CO2 form ca. 2 M (NH4)2CO3 and 2.5‐3 M ”free” NH3.
• Net leach reaction:• M(s) + ½ O2(g) + 2 NH4
+ + 4NH3 = M(NH3)62+ + H2O • Salt i solution: M(NH3)62+ (kation) + CO3
2‐ (anion).
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Glencore "Murrin Murrin", W.Australia:45 000 T/a Ni HPAL Laterite operations
HPAL leachplant H2SO4
Ni‐Co refinerySO4/amm‐sulfat
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Glencore "Murrin Murrin" operations, metallurgical site
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VALE “Goro”, New Caledonia: 50 000 T/a Ni laterite HPAL with Cl‐based refinery
HPAL leach plant H2SO4 Ni‐Co refinery Cl/HCl
NiO powder
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VALE “Goro”, New Caledonia, metallurgicalsite
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C.Palmer, Queensland Nickel, Q., Australia: 32 000 T/a Ni Caron plant (NH3) with Ni‐SX
Integrated NH3/(NH4)2CO3 circuit
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Queensland Nickel operations, metallurgical site ca. mid‐2000
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Nickel Pig Iron (NPI) flowsheet, here withblast furnace.
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Global nickel market and NPI’s influence