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The processing of nickel by pressure acid leaching nickel laterite ores at 250 8C results in liquors
supersaturated with respect to aluminum, iron, and silica. These can precipitate from the liquor and
onto the autoclave interior (scaling). This reduces the availability of the autoclave. This article presents
a methodology for characterizing scale using X-ray powder diffraction (XRPD), Rietveld analysis of
the XRPD trace, and scanning electron microscopy/microprobe. This methodology is then used to
characterize three scales formed during the continuous (pilot plant) pressure acid leaching of nickel
laterites. Scales formed during the leaching of Western Australian ore, from an acid environment in
hypersaline process water, contain mainly sodium alunite/jarosite as a solid solution together with
minor hematite and amorphous silica. Scales formed during leaching of tropical nickel laterite, in
low salinity process water, consist of an aluminum-rich hydronium alunite with hematite and low
concentrations of amorphous silica. Ore mineralogy, leach liquor composition, acidity, and temperature,
as well as precipitation kinetics, all appear to influence the scale mineralogy. This article discusses
the influence of these factors on the formation of three scales.