Search Results (4)

The Greek ferronickel industry faces the challenge of restructuring and reoperation in the future, given that privatization is in progress, including the acquisition of the company’s assets for a joint venture enterprise. Within this framework, the current paper aims to contribute to the discussion about developing a new management strategy for the optimization of the pyrometallurgical process, focusing on the critical step of smelting reduction. Based mainly on industrial experience, factors which critically affect the safety and cost-effectiveness of smelting reduction are detected and presented, also by means of case studies, being classified as follows: (i) optimal raw materials’ feed management, including laterite ores (domestic or not), solid fuels and electrode paste; (ii) focus on preventive maintenance management. Substantial increase in the facilities’ operational index and cost saving is obtained; (iii) modern human resources management strategy, enhancing evaluation indicators’ use, education culture, process standardization and tacit—explicit knowledge management. Their economic footprint is discussed. Full article

The Piauí laterite (NE Brazil) was initially evaluated for Ni but also contains economic concentrations of Co. Our investigations aimed to characterise the Co enrichment within the deposit; by understanding the mineralogy we can better design mineral processing to target Co recovery. The laterite is heterogeneous on the mineralogical and lithological scale differing from the classic schematic profiles of nickel laterites, and while there is a clear transition from saprolite to more ferruginous units, the deposit also contains lateral and vertical variations that are associated with both the original intrusive complex and also the nature of fluid flow, redox cycling and fluctuating groundwater tables. The deposit is well described by the following six mineralogical and geochemical units: SAPFE, a clay bearing ferruginous saprolite; SAPSILFE, a silica dominated ferruginous saprolite; SAPMG, a green magnesium rich chlorite dominated saprolite; SAPAL, a white-green high aluminium, low magnesium saprolite; saprock, a serpentine and chlorite dominated saprolite and the serpentinite protolith. Not all of these units are ‘ore bearing’. Ni is concentrated in a range of nickeliferous phyllosilicates (0.1–25 wt%) including serpentines, talc and pimelite, goethite (up to 9 wt%), magnetite (2.8–14 wt%) and Mn oxy-hydroxides (0.35–19 wt%). Lower levels of Ni are present in ilmenites, chromites, chlorite and distinct small horizons of nickeliferous silica (up to 3 wt% Ni). With respect to Co, the only significant chemical correlation is with Mn, and Mn oxy-hydroxides contain up to 14 wt% Co. Cobalt is only present in goethite when Mn is also present, and these goethite grains contain an average of 0.19 wt% Co (up to a maximum of 0.65 wt%). The other main Co bearing minerals are magnetite (0.41–1.89 wt%), chlorite (up to 0.45 wt%) and ilmenite (up to 0.35 wt%). Chemically there are three types of Mn oxy-hydroxide, asbolane, asbolane-lithiophorite intermediates and romanechite. Spatially resolved X-ray absorption spectroscopy analysis suggests that the Co is present primarily as octahedrally bound Co³⁺ substituted directly into the MnO₆ layers of the asbolane-lithiophorite intermediates. However significant levels of Co²⁺ are evident within the asbolane-lithiophorite intermediates, structurally bound along with Ni in the interlayer between successive MnO₆ layers. The laterite microbial community contains prokaryotes and few fungi, with the highest abundance and diversity closest to ground level. Microorganisms capable of metal redox cycling were identified to be present, but microcosm experiments of different horizons within the deposit demonstrated that stimulated biogeochemical cycling did not contribute to Co mobilisation. Correlations between Co and Mn are likely to be a relic of parent rock weathering rather than due to biogeochemical processes; a conclusion that agrees well with the mineralogical associations. Full article

Nickel (Ni) and cobalt (Co) are relevant technological metals for the future of the lithium-ion battery (LIB) industry. Based on the current and projected demand for these, an increased interest in developing processing routes to exploit lateritic occurrences has been observed, as these are reported as critical raw materials for future mineral–metallurgical industry. However, the content of Ni and Co in such ores is minimal and requires impracticable mineral-processing operations for concentration before metal extraction. It was identified that information regarding the sulfation roasting of this material is scarce on what concerns the iron sulfates interaction as a function of the temperature. Based on that context, the present work has its purposes associated with the proposition of an alternative chemical pretreatment to upgrade the content of metals of technological interest in lateritic ores through a simple roast–leach process. Thus, the chemical interactions between the mineral sample and iron (III) sulfate (Fe₂(SO₄)₃) through thermodynamic simulations and experimental procedures were explored. The latter included specific water leaching practices for the selective concentration of metals. The equilibrium calculations indicate that Fe₂(SO₄)₃ and FeSO₄ tend to decompose at lower temperatures, and considering the higher stability of other metal sulfates, it could be an interesting reagent in this type of process. Regarding the experimental results, the characterization of materials indicates a recovery of Co as high as 73.4 wt.% after sulfation roasting at 500 °C followed by water leaching, with the full content of Iron (Fe) being reported in the insoluble phase. Based on these findings, the present development could be an interesting alternative to consider within operations for the chemical upgrade of cobalt in such types of mineralogical occurrences. Full article

There is considerable interest in the development of new processes to extract the nickel from the oxidic nickeliferous laterite deposits, as the global nickel sulphide resources are rapidly becoming more difficult to access. In comparison to sulphide ores, where the nickel-containing mineral can be readily concentrated by flotation, nickel laterites are not amenable to significant upgrading, due to their complex mineralogy. In this paper, firstly, a brief overview of the conventional techniques used to process the nickeliferous limonitic laterites is given, as well as a review of current research in the area. Secondly, a thermodynamic model is developed to simulate the roasting process and to aid in the selection of process parameters to maximize the nickel recovery and grade and also to minimize the magnetite content of the concentrate. Thirdly, a two-stage process involving reduction roasting and thermal growth in either a tube furnace or a rotary kiln furnace, followed by magnetic separation, was investigated. Thermogravimetric, differential thermal and mineral liberation analyses techniques were utilized to further understand the process. Finally, the nickel grades and recovery results were compared to those available in the literature. Full article