Nickel / Cobalt Laterite Processes

A short training for SPA Geologists

October 2004
By Boy Adhitya
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 degree than limonite.
-Nickel is commonly present in silicates, clay goethite, and wad material.
-Saprolite generally contains 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.

Metallurgical Implications
- Physically

upgrading for example by removing coarse silica.

- Moisture content
major energy consumer for processes
-Ores are mineralogical and chemically complex
-Various Zones differ significantly
limit the applicability of a
particular process
-Processing routes
must be able to reject the large Fe, Si and
MgO contents.
-High Fe 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

Worlds Land Based Nickel Resources

and Primary Nickel Production
(Resources Distribution by Contained Nickel)

World Ni Resource on Land

Primary Ni Production

Sulfide

Laterite

Laterite

Sulfide

Mt Resource

% Ni

Mt Ni

% of Total

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 by Contained Nickel)

Laterites

Mt of Resources

%Ni

Mt Ni

12600

1.28

161

Typical Feed Compositions

for Various Laterite Operations
Analysis, wt. %

Moa Bay

Murrin
Murrin

SLN

Cerro
Matoso

P.T. Inco

Process

PAL

PAL

Fe-Ni
Smelting

Fe-Ni
Smelting

Matte
Smelting

Ore Type

Limonite

Nontronite Garnierite

Hi Silica
Saprolite

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

15

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 &
Reduction

CCD &
Neutralization

Smelting

Ammoniacal
leaching

Precipitation &
Redesolution
(Optional)

Refining or
Converting

Purification and
Recovery

Purification and
Recovery

FeNi or Matte

Ni and Co

Ni and Co

Smelting

Caron Process

PAL

Laterite Slag Melting Point

vs. S/M Ratio
T,OC

Electric Furnace Slag Compositions Superimposed

On the FeO-MgO-SiO2 Phase Diagram
20FeO

1700

25FeO

T,K
2000

30FeO

1900
1600

1800
1500

1700
1400

1600
1300
3
CERRO MATOSO

P.T. INCO

2
NOTE 1

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.

PT INCO - Indonesia

INCO

Dry Dust
Wet Ore Stockpile

HSFO
Air

Rock

West Block (Reject)

ESP

M.C

Dryer Kiln
DKP

East Block (Crushed)

Liquid Sulphur

HSFO
Air

Reduction Kiln

Hot Calcine (700C)

Stack

E.L

E.L

Scrubber

Dried Ore Storage

E.L

500 T
BIN

ESP

M.C

Dry Dust

Slag to Disposal area (1550C)

THICKENER

Electric Furnace

Slurry

Furnace Matte (1380C)

Silica Flux
Scrap

Fluid Bed Drier

Oversize
(Recycle to Converter)

Air

Converter
Matte Cast
Water (Hi pressure)

Granulated
Matte

100 T
BIN

Diesel
Air

Market

Granulation
Packing

SIMPLIFIED FLOW SHEET

Pugmill
Dust

Recycle
to dryer

PT INCO - Indonesia

INCO

Dried Ore
Storage 1

REDUCTION
KILN

ELECTRIC
FURNACE

Furnace 1
EB

Kiln 1

DRYER

CONVERTER

PS2
Dryer 1

Kiln 2

Dryer 2

Kiln 3

Furnace 2

Furnace 3

PRODUCT
DRYER

PS3

SHIPPING
WB
SCREENING
STATION PRODUCT

Dryer 3

Kiln 4

Furnace 4

PS4
Reverts
to Kiln

Dried Ore
Storage 2

Kiln 5

Slag to Disposal

CHEMICAL REACTIONS
REDUCTION KILNS
REDUCTION:
NiO + C Ni + CO
NiO + CO Ni + CO2
NiO + H2 Ni + H2O
CoO + C Co + CO
CoO + CO Co + CO2

ELECTRICAL FURNACES
NiO + C Ni + CO
3FeS + 3NiO Ni3S2 + 3FeO
FeS + NiO NiS + FeO
Fe3O4 + C 3FeO + CO
FeO + C Fe + CO
Fe + NiO FeO + Ni

CoO + H2 Co + H2O
Fe2O3 + 3C 2Fe + 3CO
Fe2O3 + 3CO 2Fe + 3CO2

NiO + CO Ni + CO2
}

Fe3O4 + CO FeO + CO2

FeO + CO Fe + CO2

3Fe2O3 + H2 2Fe3O4 + H2O

Fe3O4 + H2 3FeO + H2O

FeO + SiO2 FeO.SiO2

Fe3O4 + SiO2 Fe3O4.SiO2

SULFIDATION:
3Ni + S2 Ni3S2
Ni3S2 + S2 6NiS
2Fe+ S2 2FeS

NiO + SiO2 NiO.SiO2

CoO + SiO2 CoO.SiO2

PT INCO - Indonesia

INCO

DRYER FLOW SHEET

DKD
Wet Ore Stockpile
(SSP)
Pugmill Dust

Multi
Clone
Trommel
Screen

DKF
Dryer Kiln
HSFO
& AIR
DKR

Secondary
Trommel

BP
DKP

ROCK
100T

BIN

WBO
EBO

Symon
Crusher

Reject rock

ESP
D 1,2+3

Pugmill
Auto
Sampler

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

DRIED ORE STORAGE

Liquid
Sulphur
REDUCTION KILN

Coal

Hot Calci
RK 1,2,3

Scrubber

To Furnace
Multi
Clone

500 T
BIN

HSFO
AIR

100 T
BIN

Pugmill Dust

ESP

Stack

RK4 & 5

THICKENER

Recycle
To Dryer

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

Electrode

To
Thickener

Dust

Electrode

Quench
Chamber

To Stack

Electrode

From Red Kiln

To Stack

Dust

Quench
Chamber
To
Thickener

CALCINE
SLAG

Matte
MATTE

ELECTRIC FURNACE
To Converter

Slag
To Dispossal area

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
Conv.Slag

Dust

Drop
Chamber

ESP
F
Stack

CONVERTER
Air

Conv.Slag
Recycle to System
High Nickel
Low Nickel

MATTE CAST

Granulated Matte
To Product Dryer
Water
(Hi Pressure)

Granulation Pit

Fines Matte

Lamela
Thikener

Recycle to System
To Disposal area

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
-