Recovery of valuable metals from a low-grade nickel ore using an ammonium sulfate roasting-leaching process

Metal leaching from a low-grade nickel ore was investigated using an ammonium sulfate roasting-water leaching process. The nickel ore was mixed with ammonium sulfate, followed by roasting and finally leaching with water. During the process the effects of the amotmt of ammonium sulfate, roasting temperature, and roasting time on the leaching recovery of metal elements were analyzed. The optimum technological parameters were determined as follows： ammonium sulfate/ore ratio, 0.8 g/g; roasting temperature, 400℃; and roasting time, 2 h. Under the optimum condition the leaching recoveries ofNi, Cu, Fe, and Mg were 83.48%, 76.24%, 56.43%, and 62.15%, respectively. Furthermore, the dissolution kinetics of Ni and Mg from the nickel ore was studied. The apparent activation energies for the leaching reaction of Ni and Mg were 18.782 and 10.038 kJ.mo1-1, which were consistent with the values of diffusion control reactions. Therefore, the results demonstrated that the leaching recoveries of Ni and Mg were controlled by diffusion.

Generation process of FeS and its inhibition mechanism on iron mineral reduction in selective direct reduction of laterite nickel ore

Numerous studies have demonstrated that Na2SO4 can significantly inhibit the reduction of iron oxide in the selective reduction process of laterite nickel ore. FeS generated in the process plays an important role in selective reduction, but the generation process of FeS and its inhibition mechanism on iron reduction are not clear. To figure this out, X-ray diffraction and scanning electron microscopy analyses were conducted to study the roasted ore. The results show that when Na2SO4 is added in the roasting, the FeO content in the roasted ore increases accompanied by the emergence of FeS phase. Further analysis indicates that NaeS formed by the reaction of Na2SO4 with CO reacts with SiO2 at the FeO surface to generate FeS and Na2Si2Os. As a result, a thin film forms on the surface of FeO, hindering the contact between reducing gas and FeO. Therefore, the reduction of iron is depressed, and the FeO content in the roasted ore increases.

Kinetic study on leaching of nickel from Turkish lateritic ore in nitric acid solution

Dissolution kinetics of nickel from lateritic ore in nitric acid solution was investigated. Experimental parameters used were stirring speed(100-600 r/min), temperature(40-96 °C), nitric acid concentration(0.1-2 mol/L) and particle size(<106 μm). The shrinking core model was applied to the results of experiments investigating the effects of leaching temperature in the range of 40-90 °C and nitric acid concentration in range of 0.1-2 mol/L on nickel dissolution rate. The kinetic analysis shows that the nickel dissolution from lateritic ore could be described by diffusion model. The activation energy(E_a) for the dissolution reaction is calculated as 79.52 kJ/mol.

A green process for recovering nickel from nickeliferous laterite ores

A novel process was proposed for recovering nickel from nickeliferous laterite ores.First of all,silicon and magnesium were removed from lateritic ore by high concentration sodium hydroxide leaching and carbonation respectively,so as to enrich nickel. Then the method of ammonia carbonate leaching was adopted to recover nickel from the carbonized slag,and the remaining residue was used as a raw material for recovering iron.The effects of temperature,ammonia carbonate concentration,liquid/solid ratio and stirring speed on the recovery of nickel were examined.When the leached residue reacted with ammonia carbonate(6 mol·L- 1)in a ratio of liquid-to-solid of 5-1 at 60℃for 150 min at the stirring speed of 300 r·min- 1,approximate more than 95%nickel was recovered.During the whole process,there was no contamination produced and the chemical raw materials were recycled,thus the process was a green technology that having good social benefit.

Mechanism of Mg2+ dissolution from olivine and serpentine: Implication for bioleaching of high-magnesium nickel sulfide ore at elevated pH

To inhibit the dissolution of Mg^2+ during the bioleaching process of high-magnesium nickel sulfide ore, the effect of major bioleaching factors on the dissolution of Mg^2+ from olivine and serpentine was investigated and kinetics studies were carried out. The results indicated that the dissolution rate-controlling steps are chemical reaction for olivine and internal diffusion for serpentine. The most influential factor on the dissolution of Mg^2+ from olivine and serpentine was temperature, followed by p H and particle size. A novel method of bioleaching at elevated pH was used in the bioleaching of Jinchuan ore. The results showed that elevated pH could significantly reduce the dissolution of Mg^2+ and acid consumption along with slightly influencing the leaching efficiencies of nickel and cobalt. A model was used to explain the leaching behaviors of high-magnesium nickel sulfide ore in different bioleaching systems. The model suggested that olivine will be depleted eventually, whereas serpentine will remain because of the difference in the rate-controlling steps. Bioleaching at elevated pH is a suitable method for treating high-magnesium nickel sulfide ores.

Process Mineralogy of Lateritic Nickel Ore

This paper presents a methodology for studying low grade lateritic nickel ore, which usually presents complex mineralogy, with widespread nickel in several mineral phases. The study is focused on determining the mineralogy and the distribution of nickel in the bearing minerals. Laboratory assays comprise homogenization, sampling and particle size analysis. Chemical analyses by X-ray fluorescence are performed in all fractions sizes, while mineralogical assessments by X-ray diffraction are carried out for head sample. The mineralogical composition of the samples and the partition of main elements in the bearing minerals are assayed by size fraction through automated image analysis software (MLA) coupled to a scanning electron microscope (SEM). The chemical compositions of the several minerals identified in MLA are determined during systematic observations on SEM with energy dispersive spectrometer (EDS).

Evolution of ferronickel particles during the reduction of low-grade saprolitic laterite nickel ore by coal in the temperature range of 900–1250℃with the addition of CaO–CaF_(2)–H_(3)BO_(3)

The method of producing ferronickel at low temperature(1250–1400℃)has been applied since the 1950s at Nippon Yakin Kogyo,Oheyama Works,Japan.Limestone was used as an additive to adjust the slag composition for lowering the slag melting point.The ferronickel product was recovered by means of a magnetic separator from semi-molten slag and metal after water quenching.To increase the efficiency of magnetic separation,a large particle size of ferronickel is desired.Therefore,in this study,the influences of CaO,CaF_(2),and H_(3)BO_(3) additives on the evolution of ferronickel particle at≤1250℃were investigated.The experiments were conducted at 900–1250℃with the addition of CaO,CaF_(2),and H_(3)BO_(3).The reduction processes were carried out in a horizontal tube furnace for 2 h under argon atmosphere.At 1250℃,with the CaO addition of 10 wt%of the ore weight,ferronickel particles with size of 20μm were obtained.The ferronickel particle size increased to 165μm by adding 10 wt%CaO and 10 wt%CaF_(2).The addition of boric acid further increased the ferronickel particle size to 376μm,as shown by the experiments with the addition of 10 wt%CaO,10 wt%CaF_(2),and 10 wt%H_(3)BO_(3).

Two-stage reduction for the preparation of ferronickel alloy from nickel laterite ore with low Co and high MgO contents

The preparation of ferronickel alloy from the nickel laterite ore with low Co and high MgO contents was studied by using a pre-reduction-smelting method. The effects of reduction time, calcination temperature, quantity of reductant and calcium oxide (CaO), and pellet diameter on the reduction ratio of Fe and on the pellet strength were investigated. The results show that, for a roasting temperature > 800 A degrees C, a roasting time > 30 min, 1.5wt% added anthracite coal, 5wt% added CaO, and a pellet size of similar to 10 mm, the reduction ratio of Fe exceeds 70% and the compressive strength of the pellets exceeds 10 kg per pellet. Reduction smelting experiments were performed by varying the smelting time, temperature, quantity of reductant and CaO, and reduction ratio of Fe in the pellets. Optimal conditions for the reduction smelting process are as follows: smelting time, 30-45 min; smelting temperature, 1550A degrees C; quantity of reductant, 4wt%-5wt%; and quantity of CaO, 5wt%; leading to an Fe reduction ratio of 75% in the pellets. In addition, the mineral composition of the raw ore and that during the reduction process were investigated by process mineralogy.

Making Ferronickel from Laterite Nickel Ore by Coal-Based Self-Reduction and High Temperature Melting Process

Based on the process of coal-based self-reduction and melting separation at high temperature, it was investigated that the effect of process factors on the reduction of iron and nickel oxide, the metal yield and the nickel content in ferronickel about the laterite nickel ore, was from Philippines and contented low nickel, high iron and aluminum. The results showed that if the C/O mole ratio was not higher than 0.5 and the reduction temperature was kept as 1200°C and then increased up to 1500°C, the metal could not separate from molten slag for the A series of experiments, which were only added CaF2. However, when the C/O ratio was added up to 0.6 - 0.8, the metal could separate well from the slag, and the yields of Fe and Ni increased gradually. But the nickel content in the metal declined from 1.79% to 1.34%. When the C/O ratio increased to 1.2, and the temperature of melting products obtained at 1200°C and rose to 1550°C, the separation of metal from slag could not be realized in B group of tests, which were only added hydrated lime. However, when both of CaF2 and hydrated lime were added, the metal could separate from slag in C group. In order to increase the content of nickel in the metal, it is necessary to restrain the reduction of iron oxide. When the C/O mole ratio is 0.6, the nickel content of metal could be 1.79%, which was higher than the theoretical ratio 1.65% of Ni/(Ni + Fe) of the latcritic nickel ore, but the yield of nickle was only 71.3%.

Leaching of nickel laterite ore assisted by microwave technique

The application of microwave technique in the hydrometallurgy of nickel laterite ores was described.The mixture of nickel laterite ores and sulfuric acid was pre-treated by microwave irradiation.The dissolving of nickel was conducted in hot water at the atmospheric pressure.The effects of factors,such as microwave power,microwave irradiation time,and sulfuric acid dosage, were investigated.In microwave field,the migration of ionic species and/or rotation of dipolar species promote the liquid?solid reaction process due to the increased contact area of reactants and leaching reaction rate constant.Thanks to the strengthening action of microwave,the microwave-assisted leaching process has its advantages,such as higher extracting rate than conventional atmospheric leaching,and no need for high-pressure operation as high pressure acid leaching(HPAL).The ferric iron in leaching solution could be effectively removed by sodium jarosite process with a little loss of nickel in the jarosite precipitate.

Leaching of magnesium from desiliconization slag of nickel laterite ores by carbonation process

The leaching of magnesium from desiliconization slag of nickel laterite ores by carbonation process was studied.The influence of various parameters was investigated to optimize the conditions and determine the kinetics of the reaction.The results show that with increasing stirring speed,liquid-to-solid ratio and reaction time,and decreasing temperature,the leaching rate of magnesium enhances.The leaching process of the desiliconization slag in the range of 288-298 K is controlled by the surface chemical reaction model.The apparent activation energy is-20.45 kJ/mol,and the kinetics model is obtained.

Synthesis and characterization of Co_3O_4 prepared from atmospheric pressure acid leach liquors of nickel laterite ores

A chemical precipitation-thermal decomposition method was developed to synthesize Co3O4 nanoparticles using cobalt liquor obtained from the atmospheric pressure acid leaching process of nickel laterite ores. The effects of the precursor reaction temperature, the concentration of Co2＋, and the calcination temperature on the specific surface area, morphology, and the electrochemical behavior of the ob- tained Co304 particles were investigated. The precursor basic cobaltous carbonate and cobaltosic oxide products were characterized and ana- lyzed by Fourier transform infrared spectroscopy, thermogravimetric differential thermal analysis, X-ray diffraction, field-emission scanning electron microscopy, specific surface area analysis, and electrochemical analysis. The results indicate that the specific surface area of the Co3O4particles with a diameter of 30 rim, which were obtained under the optimum conditions of a precursor reaction temperature of 30℃, 0.25 mol/L Co2＋, and a calcination temperature of 350℃, was 48.89 m2/g. Electrodes fabricated using Co3O4 nanoparticles exhibited good electrochemical properties, with a specific capacitance of 216.3 F/g at a scan rate of 100 mV/s.

Slag Resistance of Refractories for Direct Reduction of Laterite Nickel Ores in Rotary Kilns

Aiming at prolonging the service life of refractories for direct reduction of laterite nickel ores in rotary kilns,the slag resistance of ten materials(corundum bricks,chrome corundum bricks,silicon nitride bonded silicon carbide bricks,high alumina silicon carbide bricks,high alumina bricks,magnesia chrome bricks,magnesium aluminate spinel bricks,spinel chrome corundum bricks,chrome corundum castables and magnesia alumina chrome composite spinel bricks)was evaluated by rotary slag tests,which simulate the service conditions in rotary kilns.The corroded residual bricks were analyzed by SEM and EDS.The results show that the magnesia alumina chrome composite spinel brick possesses the advantages of magnesium aluminate spinel bricks and chrome corundum bricks;MgO-rich spinel can absorb the penetrated ferric oxide,and forms a dense zeylanite layer,which prevents the penetration of the molten laterite nickel ores;therefore,it is an ideal lining of rotary kilns for direct reduction of laterite nickel ores.

Process development for the direct solvent extraction of nickel and cobalt from nitrate solution:aluminum,cobalt,and nickel separation using Cyanex 272

A direct solvent extraction（DSX） process for purifying nickel and cobalt from the nitric acid leach solution of nickel laterite ores was conceived and experimentally probed. The proposed process consists of two solvent extraction（SX） steps but with only one extractant - bis（2,4,4-trimethylpentyl）phosphinic acid（Cyanex？ 272） - used in both steps. The first extraction step involved the removal of aluminum and zinc, whereas the second extraction step involved the separation of cobalt along with manganese from nickel. The experimental results showed essentially quantitative removal of aluminum（〉97%） and zinc（〉99%） in a single extraction stage using 20vol% Cyanex 272 at pH 2.1. Some cobalt（32%） and manganese（55%） were co-extracted but were easily scrubbed out completely from the loaded organic phase using dilute sulfuric acid at pH ≤ 1.38. Cobalt and manganese in the first extraction raffinate were extracted completely in four extraction stages at staggered pH values of 4.0, 4.4, 4.5, and 4.0 in the first, second, third, and fourth stages, respectively, using also 20vol% Cyanex 272. A small amount of nickel（up to 6.6%） was co-extracted but was easily scrubbed out completely with dilute sulfuric acid at pH 2.0. A flow diagram showing the input and output conditions and the metals separated under the deduced optimum conditions is presented.

Time scales and length scales in magma ?ow pathways and the origin ofmagmatic Ni-Cu-PGE ore deposits

Ore forming processes involve the redistribution of heat, mass and momentum by a wide range of processes operating at different time and length scales. The fastest process at any given length scale tends to be the dominant control. Applying this principle to the array of physical processes that operate within magma flow pathways leads to some key insights into the origins of magmatic Ni-Cu-PGE sulfide ore deposits. A high proportion of mineralised systems, including those in the super-giant Noril'sk-Talnakh camp, are formed in small conduit intrusions where assimilation of country rock has played a major role. Evidence of this process is reflected in the common association of sulfides with varitextured contaminated host rocks containing xenoliths in varying stages of assimilation. Direct incorporation of S-bearing country rock xenoliths is likely to be the dominant mechanism for generating sulfide liquids in this setting. However, the processes of melting or dissolving these xenoliths is relatively slow compared with magma flow rates and, depending on xenolith lithology and the composition of the carrier magma, slow compared with settling and accumulation rates. Chemical equilibration between sulfide droplets and silicate magma is slower still, as is the process of dissolving sulfide liquid into initially undersaturated silicate magmas. Much of the transport and deposition of sulfide in the carrier magmas may occur while sulfide is still incorporated in the xenoliths, accounting for the common association of magmatic sulfide-matrix ore breccias and contaminated "taxitic" host rocks. Effective upgrading of so-formed sulfide liquids would require repetitive recycling by processes such as reentrainment, back flow or gravity flow operating over the lifetime of the magma transport system as a whole. In contrast to mafic-hosted systems, komatiite-hosted ores only rarely show an association with externally-derived xenoliths, an observation which is partially due to the predominant formation of ores in lava flows rather than deep-seated intrusions, but also to the much shorter timescales of key component systems in hotter, less viscous magmas. Nonetheless, multiple cycles of deposition and entrainment are necessary to account for the metal contents of komatiite-hosted sulfides. More generally, the time and length scale approach introduced here may be of value in understanding other igneous processes as well as non-magmatic mineral systems.

Nickel solvent extraction from cold purification filter cakes of Angouran mine concentrate using LIX984N

Cold purification filter cakes generated in the hydrometallurgical processing of Angouran mine zinc concentrate commonly contain significant amounts of Zn, Cd, and Ni ions and thus are valuable resources for metal recovery. In this research, a nickel containing solution that was obtained from sulfuric acid leaching of the filter cake following cadmium and zinc removal was subjected to solvent extraction experiments using 10vol%LIX984N diluted in kerosene. Under optimum experimental conditions （pH 5.3, volume ratio of organic/aqueous （O：A） = 2：1, and contact time -5 min）, more than 97.1% of nickel was extracted. Nickel was stripped from the loaded organic by contacting with a 200 g/L sulfuric acid solution, from which 77.7% of nickel was recovered in a single contact at the optimum conditions （pH 1-1.5, O：A =5：1, and contact time =15 min）.

The Occurrence of Sc, Co and Ni in Manganese Ore from Western China

China’s manganese resources are usually associated with the valuable elements such as silver, lead, zinc, cobalt, nickel, scandium, etc which should be comprehensively recovered during the manganese beneficiation. A manganese ore from western China contains Mn 23.18%, Co 0.073%, Ni 0.21% and Sc 0.013%. The mineralogy composition of ore and the occurrence of associated elements of Sc, Co as well as Ni are studied in this paper. According to the results, the manganese minerals in this ore are mainly lithiophorite and a little secondary pyrolusite. The lithiophorite in this ore is rich in aluminum and actually it is the generic name for the multi-mineral aggregates mixed by silicon, aluminum and iron, which is quite different with the ordinary psilomelane. There is not any Sc, Ni or Co mineral in this ore and more than 98% of Sc, Ni and Ni exists in lithiophorite and pyrolusite. The distribution of Sc, Co and Ni in lithiophorite is further studied by EPMA and the results indicate that Sc and Co in lithiophorite is sparse and dispersed distribution while Ni usually distributes in the argillaceous lithiophorite and is local enrichment. Reduction-sulfuric acid leaching tests show that the dissolution of Sc and Co happens before lithiophorite dissolves; the dissolution rate of Sc and Co is almost the same, which is significantly higher than the dissolution rate of manganese. However, the dissolution rate of Ni is extremely low with the dissolution of manganse, which indicates that Ni is hard to dissolve and its dissolution rate obviously lags behind that of Mn, Sc and Co. The conclusion can be drawn that Sc and Co exist in the lithiophorite crystals as interface adsorption while Ni exists in the clay (kaolinite) mixed up with lithiophorite as interface adsorption. The conclusion indicates that Sc and Co can dissolve before the dissolution of manganese at a high dissolution rate in the hydrometallurgical process while Ni is also into the solution through desorption from the interface of clay but its dissolution rate is rather slow because of the insoluble nature of clay.

Influence of laterite nickel ore on extracting iron from Bayer red mud by carbothermal smelting reduction

In view of the difficulty of extracting iron from Bayer red mud,a new idea of adding laterite nickel ore into red mud was proposed to prepare a high value-added product.Toward this,the influences of laterite nickel ore on thermodynamic reaction,slagging and smelting reduction of extracting iron from red mud were studied.The results indicated that the product of extracting iron from red mud(R100)was changed with the addition of laterite nickel ore(R70L30).The slag of R100 was strongly basic,while the R70L30 was weakly acidic with composition closer to the ideal blast furnace slag.The metal recovery of R100 was 75.16%and that of R70L30 was 94.05%.At the same temperature,the slag viscosity of R70L30 was significantly lower than that of R100,which proved that laterite nickel ore can adjust the basicity,reduce melting point of slag and improve metal recovery.Because Fe,Ni and Cr in red mud and laterite nickel ore can be reduced sufficiently,a low Ni–Cr alloy cast iron can be directly prepared.

Direct smelting process for stainless steel crude alloy recovery from mixed low-grade chromite, nickel laterite and manganese ores

Stainless steel crude alloy recovery from direct smelting of low-grade chromite, nickel laterite and manganese ores was investigated. The mixed low-grade ores were directly smelted in an elevator furnace at smelting temperatures ranging from 1550 to 1600 ℃. Smelting experiments were conducted in a laboratory elevator furnace equipped with 8 U-shaped high- quality molybdenum disilicide heating elements. A low-grade coal was used as the reductant. Experimental results showed that the recovery of Fe, Cr, Ni, Mn and Si within the alloy increased from 34.22, 60.27, 57.14, 25.42 and 13.02% to 69.91, 99.26, 86.02, 60.8 and 34.21%, respectively, when the temperature was increased from 1550 to 1600 ℃. There was a general increase in the total recoveries of Fe, Cr, and Ni in the alloy with CaO addition increasing from 0.4 g up to 1.2 g. However, the recoveries of Mn and Si vividly decreased as the CaO contents were increased. In general, the recoveries of the metal contents of the crude alloy increase with the increase in the amount of manganese ore. Compared to the recoveries of Fe, Cr, and Ni when CaO was added, the recoveries of Fe, Cr and Ni were lower when manganese ore was used as an additive.