Nickel / Cobalt Laterite Processes

A short training for SPA Geologists

February 2005
By Boy Adhitya
Presented by : Frans Attong
Adopted from ALTA 1997, Ni/Co Laterite Project Development Seminar
And
A presentation MS 2004-133rd Annual Meeting & Exhibition,
International Laterite Symposium 2004 by Ashok Davi
 Mineralogy And ore Composition

Idealized Orebody Profile

Cap
-Lateritic soils and re-crystallized iron oxides formed by sequential leaching and re precipitation.
-Generally has a low nickel grade, therefore classified as overburden.

Limonite
-Main consituents are goethite, chromite, manganese wad (asbolane), silica and silicates.
-Most of Nickel is in Goethite (Fe,Ni)O(OH) nH2O
-Most of Cobalt is in the coarser grained wad, Mn, Fe, Co, Ni Oxide

Altered Peridotite
-Generally called silicate or saprolite zone
-In dry climates saprolite my contain upper clay rich zone.
-Saprolite Zone can also contain wad and chromite to lesser dgree than limonite.
-Nickel is commonly present in silicates, clay goethite, and wad material.
-Saprolite generally conrains portion of reject low grade bed rock and silica boxwork. Nickel enriched rim
may occur around rock pieces.

Bed Rock
- Low grade Peridotite, which is not mined. However nickel enrichment can occur in upper cracks.
 Mettalurgical Implications
-Physically upgrading is generally limited to rejection of barren rocks, or possibly
Chromite. However, occasionally it is possible to achieve more substantial upgrading,
for example by removing coarse silica.
-Moisture content is a major energy consumer for processes which include drying,
such as smelting and reduction roast-ammonia leaching.
-Ores are mineralogical and chemically complex, which is challenging for chemical
processes.
-Various Zones differ significantly, which may limit the applicability of a particular
process to only part of the ore reserves.
-Processing routes must be able to reject the large iron, silica and magnesia contents.
-High iron content is a problem for acid leaching processes in general. Magnesia and
alumina are also acid consumers.
-Aggressive leaching conditions are required to take nickel into solution.
-Si/Mg ratio has important implications for smelting processes.
-Presence of clays generally has adverse impact on hydrometallurgical operations, e.g.
settling, pumping, agitation.
-Unlike sulphide ore treatment, sulphur is not released in the extraction of nickel and
cobalt, which has environmental benefits.
-Cobalt is potentially valuable by-product, which is a major consideration in selection
of a processing route. Cobalt level is highest in the limonitic zone.
-Chromite could be considered as a by-product in some cases, and its recovery by
gravity separation would constitute minor upgrading
 Worlds Land Based Nickel Resources
and Primary Nickel Production
(Resources Distribution by Contained Nickel)

World Ni Resource on Land Primary Ni Production

28%
Sulfide 42%
Laterite
Laterite Sulfide

58%
72%

Mt % Ni Mt Ni % of Total
Resource
Sulfide 10500 0.58 62 27.8%
Laterite 12600 1.28 161 72.2%
Total 23100 0.97% 223 100
Commercial Processes
Four basic process routes in current use for latterites :
-Pyrometallurgical : - Ferronickel smelting
- Matte smelting
-Hydrometalurgical : - Pressure Acid Leach
-Pyromet/hydromet : - Reduction roast ammonia leach

Operating Plants
-Ferronickel smelting is still the dominating process
-Smelting is generally applied to higher grade feed, most are > 1.7% Ni.
Hydrometallurgical plants generally process < 2% Ni.
 World Nickel Laterite Resources
(Distribution
World Nickel Lateriteby Contained
Resources Combined Nickel)
HYDROMET & PYRO
(Distribution by Contained Nickel)

ASIA & EUROPE AUSTRLIA

4% OTHER 20%
2% AFRICA
8%
NEW CAL
21%
C&S AMERICA
9%

PHILIPINNES
CARRIBEAN
17% INDONESIA
7%
12%

Mt of Resources %Ni Mt Ni
Laterites 12600 1.28 161
Typical Feed Compositions
for Various Laterite Operations

Analysis, wt. Moa Bay Murrin SLN Cerro P.T. Inco

% Murrin Matoso
Process PAL PAL Fe-Ni Fe-Ni Matte
Smelting Smelting Smelting
Ore Type Limonite Nontronit Garnierite Hi Silica Saprolite
e Saprolite
Ni 1.3 1.3 2.7 2.9 1.8
Co 0.15 0.09 0.07 0.07 0.07
Fe 47.5 22 14 14 18
Al 4.5 2.5
Mg 1.0 4 15 9 10
SiO2 3.7 42 37 46 34
Mn 0.75 0.4
Laterite Processes
(Generalized Block Flow Diagram)

Laterite Ore Laterite Ore Laterite Ore

Drying Drying High Pressure

Leaching

Calcine/Reduction Calcine & CCD &

Reduction Neutralization

Smelting Ammoniacal Precipitation &

leaching Redesolution
(Optional)

Refining or Purification and Purification and

Converting Recovery Recovery

FeNi or Matte Ni and Co Ni and Co

Smelting Caron Process PAL

Laterite Slag Melting Point
vs. S/M Ratio
Electric Furnace Slag Compositions Superimposed
On the FeO-MgO-SiO2 Phase Diagram
T,OC T,K

20FeO 25FeO 30FeO 2000

1700

1900
1600

1800
1500

1700
1400

1600
1300
1 2 3 4 5 6 7 8
CERRO MATOSO
NOTE 1

P.T. INCO

SiO2 / MgO

NOTE 1: Japanese FE-Ni Smelters and SLN

NOTE 2: Cerro Matoso (FeO ~ 20%)
Process Description and Examples
Pyrometallurgical Processes
Fe-Ni Production

Ores suited for production of high carbon ferro-nickel have:

High nickel grade (> 2.1 % Ni)

Low Silica/Magnesia ratio, and

Low iron content (Fe/Ni ratio <6)

Examples: SLN Doniambo, Pamco, Hyuga, P.T. Aneka Tambang

Ores suited for production of low carbon ferro-nickel have:

Higher Fe/Ni ratio (6 to 12)

Relatively high-melting point slags

(Either very high S/M ratio Example: Cerro Matoso, or Low S/M ratio
Example: Falcondo)
Process Description and Examples
Pyrometallurgical Processes
Matte Production

Ores suited for production of matte have:

Relatively higher Fe/Ni ratio (6 to 12)

Relatively low melting point slags

Example: P.T. Inco

Process Description and Examples
Caron Process

Caron process could be used for limonitic ores or a

mixture of limonite and saprolite
The process can tolerate a higher amount of Mg in
the feed than the PAL processes

Examples: Nicaro, Punta Gorda, Yabulu, Nonoc

(Closed)
 Process Description and Examples
PAL Processes

PAL processes use ore that:

are predominantly limonitic, or nontronitic
in the case of dry laterites
contain some saprolite

have Mg generally limited to <4 % (At

higher Mg acid consumption is higher)
require lower Al content

Examples: Moa Bay, Murrin Murrin

 Smelting Process
Smelting process are governed by two basic chemical facts:
-Separation of Nickel from Oxide gangue components such as silica
and magnesia is readily achieved by smelting, due to large
differences in the free energies of formation.

-Only partial separation of nickel from iron is possible by selective

reduction of oxides. Reduction conditions can be set to completely
reduce nickel oxide, but part of the iron oxide is co-reduced.

Two approaches have been adopted :

-Minimise Fe/Ni ratio and accept a ferronickel product
-Add sulphur to form a nickel/iron sulfide matte, then prefentially
convert iron sulphide to oxide by blowing with air, to leave a low
iron nickel suphide matte product (for further refining).
 Ferronickel Smelting
Main reactions

Nickel and cobalt is almost totally reduced to metal by carbon monoxide (or
Hydrogen):
NiO + CO = Ni + CO2
Iron is partially reduced in three stages. The extent depends on time, temperature,
and reducing conditions
3Fe2O3 + CO = 2Fe3O4 + CO2
Fe3O4 + CO = 3FeO + CO2
FeO + CO = Fe + CO2
Iron reduction is the key control issue, as iron dilutes the product, and the ferrous
iron content of slag affects slag properties and impurities in the product.
 Ore Preparation
Depends on ore characteristics, but typically consists of coarse crushing and
screening, with rejection of coarse barren material.

Drying
Up to 250 C to drive off physically bound moisture to achieve a residual of about 15
20 % to avoid excessive dusting. Normally carried out in rotary dryer.

Screen and crushing

Trend has been towards reducing ore to minus 10 mm and including pelletizing step.
Additional coarse barren material may be rejected.

Calcination and Prereduction

-Early practice was to limit the temperature to about 700 c, which is sufficient to
drive off chemically bound moisture and preheat for smelting step.
INCO PT INCO - Indonesia
Dry Dust
Dryer Kiln M.C ESP
Wet Ore Stockpile
HSFO
Air West Block (Reject) Rock
DKP
East Block (Crushed)
HSFO
LiquidSulphur Air
Reduction Kiln
Hot Calcine (700C)

Dried Ore Storage Stack

Scrubber
500 T 100 T
M.C ESP
E.L E.L E.L BIN BIN
Dry Dust
Slag to Disposal area (1550C)

Slurry Recycle
THICKENER Pugmill
Electric Furnace to dryer
Furnace Matte (1380C) Dust
Silica Flux
Scrap Oversize
Fluid Bed Drier (Recycle to Converter)
Air

Converter Diesel
Air
Granulated
Matte Cast Matte
Water (Hi pressure)
Market
Granulation
Packing

SIMPLIFIED FLOW SHEET

INCO PT INCO - Indonesia

Dried Ore
Storage 1 REDUCTION ELECTRIC
KILN FURNACE

Furnace 1 CONVERTER
Kiln 1
DRYER
EB

PS2
Dryer 1 Kiln 2 Furnace 2
PRODUCT
DRYER

Furnace 3 PS3
Dryer 2 Kiln 3

SHIPPING

WB Furnace 4
Dryer 3 PS4
Kiln 4
SCREENING
STATION PRODUCT
Reverts
to Kiln

Kiln 5 Slag to Disposal

Dried Ore
Storage 2
CHEMICAL REACTIONS
REDUCTION KILNS ELECTRICAL FURNACES
REDUCTION: NiO + C Ni + CO
NiO + C Ni + CO 3FeS + 3NiO Ni3S2 + 3FeO
NiO + CO Ni + CO2 FeS + NiO NiS + FeO
NiO + H2 Ni + H2O Fe3O4 + C 3FeO + CO
FeO + C Fe + CO
CoO + C Co + CO
Fe + NiO FeO + Ni
CoO + CO Co + CO2
CoO + H2 Co + H2O
NiO + CO Ni + CO2
Fe2O3 + 3C 2Fe + 3CO } Fe3O4 + CO FeO + CO2
Fe2O3 + 3CO 2Fe + 3CO2 FeO + CO Fe + CO2
3Fe2O3 + H2 2Fe3O4 + H2O
Fe3O4 + H2 3FeO + H2O FeO + SiO2 FeO.SiO2
Fe3O4 + SiO2 Fe3O4.SiO2
SULFIDATION: NiO + SiO2 NiO.SiO2
3Ni + S2 Ni3S2 CoO + SiO2 CoO.SiO2
Ni3S2 + S2 6NiS
2Fe+ S2 2FeS
2FeS+ S2 2FeS2
INCO PT INCO - Indonesia
DRYER FLOW SHEET

DKD
Wet Ore Stockpile ESP
Multi
(SSP)
Clone D 1,2+3
Pugmill Dust
Trommel
DKF Screen

Dryer Kiln
BP
ROCK
HSFO DKP
Secondary
& AIR 100T
Trommel BIN
DKR WBO

EBO Pugmill
Auto
Sampler
Symon
Crusher
Reject rock Scale
Main functions of the Dryer

To remove part of the moisture from the feed.

To screen barren rocks in the case of WB.
To crush ore grading rocks in the case of EB.
To blend the recycled dust with the fresh ore
from the mine.
P.T.INCO REDUCTION KILN FLOW SHEET
Dried Ore (DKP)

Feed
Bin Liquid
DRIED ORE STORAGE
Sulphur
REDUCTION KILN
Coal
Hot Calci
To Furnace

Multi HSFO
Clone AIR
500 T 100 T
BIN BIN

Recycle
Pugmill Dust
ESP To Dryer
RK4 & 5
Stack P
P
THICKENER
Main functions of Kiln

To remove remaining free moisture of the blended ore.

To remove crystalline water (LOI) of the blended ore.
To pre-heat the charge to >700 C.
To partially reduce Ni, Co and Fe oxides to metallics.
To blend the feed prior to smelting.
To blend Carbon with the feed in controlled proportion to
control the composition of furnace matte and slag.
To sulfidize calcine to control furnace matte sulfur content.
 FURNACE FLOW SHEET
Hot Calcine (RKP)

Feed
Bin
To Stack To Stack
From Red Kiln

Electrode

Electrode

Electrode
Quench Dust Dust
Chamber Quench
Chamber
To To
Thickener Thickener

CALCINE

SLAG Slag
Matte
MATTE
To Dispossal area

ELECTRIC FURNACE

To Converter
Main functions of Furnace

To remove remaining water crystal (LOI) of calcine.

To complete reduction process using the carbon in calcine
To melt sulfide and metallic phases to form a single liquid
matte phase.
To melt the oxide phases to form a single liquid slag phase.
To separate the matte and slag phase based on density
differences.
To discard the slag containing only small amount of nickel.
To tap matte containing most of nickel for further processing
in the converters.
 CONVERTER FLOW SHEET

EFM
Silica Flux
Scrap Dust
Conv.Slag Drop
Chamber ESP

F
Stack
CONVERTER
Air Conv.Slag
Recycle to System

High Nickel
Recycle to System

Low Nickel To Disposal area

Granulated Matte
To Product Dryer

Water
(Hi Pressure) Fines Matte Lamela
Thikener

Granulation Pit
Main functions of Converter

To reduce the iron content of furnace matte by

oxidizing the iron with silica flux
To separate the iron oxide (converter slag) and matte
based on density differences.
To discard the converter slag containing only small
amount of nickel.
To tap matte containing most of nickel for granulation
Adopted from :

- ALTA 1997, Ni/Co Laterite Project Development Seminar

- A presentation MS 2004-133rd Annual Meeting & Exhibition,
International Laterite Symposium 2004 by Ashok Davi.
- PTI _Plant flow sheet , a ppt by Agus Superiadi