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Mineral Engineering Technical Services
PO Box 5778
St Georges Tce WA 6831
P: (+61 8) 9421 9000
F: (+61 8) 9325 8311
ABN 66 009 357 171
W: www.metsengineering.com
A division of Midas Engineering Group
Nickel Ore Processing Trends
The Rise of Nickel Laterites and Advances in Sulphide
Processing
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
• DISCLAIMER With respect to all the information contained herein, neither Mineral Engineering Technical Services, nor
any officer, servant, employee, agent or consultant thereof make any representations or give any
warranties, expressed or implied, as to the accuracy, reliability or completeness of the information
contained herein, including but not limited to opinions, information or advice which may be provided to
users of the document. No responsibility is accepted to users of this document for any consequence of
relying on the contents hereof.
• COPYRIGHT © Passing of this document to a third party, duplication or re-use of this document, in whole or part,
electronically or otherwise, is not permitted without the expressed written consent of Mineral
Engineering Technical Services.
• ACKNOWLEDGEMENTS This document is a dynamic record of the knowledge and experience of personnel at Mineral
Engineering Technical Services. As such it has been built upon over the years and is a collaborative
effort by all those involved. We are thankful for the material supplied by and referenced from various
equipment manufacturers, vendors, industry research and project partners.
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Key Attributes
• Working globally since 1988
• Dynamic and innovative niche consultancy
• Dedicated team providing customised service
• Specialist in mineral processing & engineering projects
• Unique solution finder
Pragmatic, efficient, complete engineering through
quality, personalised & exceptional service delivery
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Outline
• Introduction to nickel – sources and uses
• Look at the market and some interesting production statistics
• Today’s nickel processing status − Brief overview of hydrometallurgical and pyrometallurgical processes
> Their current market contribution
> Current Projects/Operations
> Process Pros and Problems
• The future of nickel processing − Overview of proposed/pipeline processes for sulphides and laterites
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Nickel Sources
• 30% of world nickel is in sulphidic form, 70% is lateritic nickel
• Image (Butt, 2007).
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Processing Background and Nickel
Uses
What do we use nickel for?
− About 70% of nickel goes into making steel (in China & also Japan)
− The remaining 30% goes into specialty products: batteries, electronics, turbines etc.
How have we traditionally sourced it?
• Sulphides have been the dominant source of nickel through the
1900’s. − Higher grades than laterites
− Processing cheaper than laterites (upgrading)
− High grade sulphide reserve levels not an issue
• Laterites have not contributed as significantly to the market until recent
times - 30% world production in 1990
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterite/Sulphide Mine Production
Trends
• Note that Indonesia has recently banned ore exports! This is putting
pressure on supply as China/Japan have to source nickel from elsewhere
in the interim (Philippines) – nickel price has risen 37% this year (dropped
6.5 % very recently due to underestimated stockpiles)
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Processing Trends by Ore Type
• >50 % of the mined laterite ore (previous slide) from the Philippines is
actually processed as iron ore.
• A lot of stockpiling in China has also reduced impact of mined ore on
actual production.
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Processing Trends by Process
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Sulphide Access and Availability
• Sulphides are still a major nickel source
• Rate of consumption exceeds rate of new deposit discovery
• Major ore types: − Massive sulphide – historically relied upon – largely gone
− Disseminated sulphides – what we are largely left with
− Today’s economic sulphide grades – 0.2 to 2%
• Mining sulphides − NiS is formed as a result of volcanic and hydrothermal activities
− Open cut mines
− Underground mines (primarily)
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Magmatic Sulphide Deposit Profile
• Orthomagmatic Nickel Sulphide Deposit Model
• Many classifications of sulphide deposits
• What is important to know from a processing point of view: − Massive sulphides (VMS) – upgrade well
− Disseminated sulphides
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Sulphide Processing
• Pyrometallurgical processes are still predominant − Flash furnaces are the conventional smelting route
• Hydrometallurgy is an emerging trend in sulphide processing due to: − Environmental pressures
− Lower grades
• Commercially applied processes include: − Pressure Oxidation (POX)
• Processes in Development include: − ACTIVOX
− CESL
− Platsol
− The Albion Process
− Bio-Heap Leaching
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Sulphide Pyrometallurgy – Smelting
• Production: − 90+% of sulphide processing
− 40% of world nickel production
• Process: − Beneficiation
− Roasting
− Smelting
− Refining – not our focus today
Pros Problems
Sulphide oxidation is exothermic SO2 production
Widely known and understood Arsenic emissions
Suitable ores running out
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Sulphide Hydrometallurgy - POX
• Process: − Comminution
− Atmospheric chloride pre-leach
− Pressure Oxidation leach
> Pure oxygen
> 22-27 bar
> 200oC
− Impurity precipitation - MHP product
• Projects: − Voisey’s Bay, Canada, 50 ktpa finished nickel
Pros Problems
Can process arsenic-bearing ores Chlorine gas handling
No SO2 produced Requires water and tailings disposal
facilities
Good cobalt extraction Limited ore applications
High pressure/temperatures
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Sulphide Hydrometallurgy - CESL
• Process − Comminution – 25 to 45 micron
− Pressure Oxidation Leach
> Sulphuric acid / chloride mix
> Pure oxygen
> 14 bar
> 150oC
− Impurity precipitation - MHP product
• Projects − Process developed by Teck Resources
− Vale Salobo copper project – piloted in 2008
Selling Points
Can deal with low grade concentrates (3%)
Can deal with high Mg-bearing ores
Laterite application has been investigated
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Sulphide Hydrometallurgy - ACTIVOX
• Process − Ultrafine grinding
− Pressure Oxidation Leach
> Sulphuric acid
> Pure oxygen
> 10 bar
> 100oC
− CCDs
− MHP product
• Projects − Developed by WMT in Perth
− Tati Nickel, Botswana
Selling Points
Milder conditions than POX/CESL
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Sulphide Hydrometallurgy - Albion
• Process − Isamill grinding
− Oxidation leach
> 1 bar
> 70oC
> Supersonic pure oxygen
− CCDs, impurity removal, MHP
• Projects − Developed by MIM (Xstrata) in 1994
− Two zinc, two gold plants
Pros Problems
Atmospheric conditions - CAPEX Isamill energy intensive
Low reagents - OPEX
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Sulphide Hydrometallurgy - Platsol
• Process − Grinding
> 120 micron
− Pressure oxidation leach
> Sulphuric acid generation
> NaCl added to leach (dissolves PGMs)
> 25 bar
> 220oC
• Projects − SGS holds the patent
− PolyMet Mining, NorthMet Project - developmental
Selling Points
Used to treat PGMs
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Summary of Vessel Processes
Pressure
(bar) Temperature
(C) P80 Grind Size
(micron) Residence
Time (hours)
POX 27 200-225 20 (Voisey’s) 2
Platsol 27 220 120
CESL 14 150 25 to 45
ACTIVOX 10 100-110 5 to 15
Albion 1 70-90 10 to 15 24
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Sulphide Hydrometallurgy – Bio Heap
Leaching
• Process − Agglomeration + Heap construction
− Bacteria and dilute sulphuric acid leach
> Atmospheric
> Autothermal
− No CCDs required
− Impurity removal, intermediate product
• Projects − Western Areas – testing
− Talvivaara, Finland - online
− Jinchuan, China – pilot
Pros
Avoid fine grinding
Low reagents
Autothermal
Applicable to low grades
Low environmental impact
Problems
Large footprint
Long residence time
Heap leach issues
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterites
• Economic grades - 1.3 to 1.8% − Saprolite typically 1.5 to 3% Ni
− Limonite typically 1.2 to 1.7% Ni
• Beneficiation difficult
• Current pyrometallurgical dealing with laterites − Ferronickel Smelting – Fe-Ni
− Nickel Pig Iron Smelting – NPI
• Current hydrometallurgical dealing with laterites − The Caron Process (pyro/hydro hybrid) – Majority
− HPAL (High Pressure Acid leaching) – Majority
− HPAL combined with AL (Atmospheric Leaching)
− HL (Heap Leaching)
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterites - Profile
• Form in the “oxidised zone”
• Laterites are generally more accessible than sulphide ores from a
mining perspective – all open cut as a result of shallow ore bodies
• Generalised ore body profile:
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterite Pyrometallurgy - Background
• 40% primary production in 2012
• Fe-Ni/NPI - What’s the difference? − Fe-Ni has an ISO classification
− NPI does not have a standard
• Uses: − Fe-Ni - 300 series of steels (e.g. 304, 316)
− NPI - 200 series of steels (construction steels)
• NPI - 19th century technology – − China brought it back to life in 2006
− A “last resort” alternative
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterite Pyrometallurgy - Ferronickel
• Process − Saprolite feedstock – Fe, Mg, Ni ratio
− Calcining 1000oC
− Smelting in RKEFs 1550oC
− Refining
• Projects − Onca Puma, Brazil (50 ktpa)
− Koniambo, New Caledonia (60 ktpa)
− Gwanyang, South Korea (30 ktpa)
− …
Pros Problems
Well understood technology Energy intensive
Environmental issues
Commercially sensitive
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterite Pyrometallurgy – Nickel Pig Iron
(NPI)
• Process: − Used with limonite
− Roasting
− Smelting - Blast furnaces, submerged arc furnaces
− Refining
• Projects: − More than 30 producers in China – 100 ktpa+
Pros Problems
Well understood technology Energy intensive
Robust – lim. and sap. Emissions
Commercially sensitive
Low grade product
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterite Hydrometallurgy - The Caron
Process
• Process − Limonite feedstock
− Calcination 850oC
− Ammonia leach/quench (150-200oC)
• Projects − Yubulu, Australia (1974)
− Punta Gorda, Cuba (1986)
− Nicaro, Cuba (1944)
Issues
Ni/Co recoveries < HPAL
Limited to low Mg ores
No longer viable greenfield process
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterite Hydrometallurgy - Pressure
Leaching (PAL/HPAL)
• Process: − Limonite feedstock (low magnesium)
− High pressure autoclaves
> Sulphuric acid
> PAL – 4 bar; HPAL – 30 bar
> 240-270oC
> Hydrolysis reaction
− Energy recovery
− CCDs
− Impurity removal
− Intermediate product
• Projects: − Moa Bay, Cuba
− Murrin Murrin, Australia
− Bulong and Cawse, Australia
− Ambatovy, Madagascar
− Goro Nickel Project
Pros
Can handle arsenic feeds
Good recoveries (>95% Ni&Co)
Fast reaction times
Cobalt credits
Problems
Exotic equipment
Commercial risk
Maintenance
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterite Hydrometallurgy – HPAL +
Atmospheric Leaching (AL)
• Process: − PAL deals with limonite feed
− AL takes PAL discharge and neutralises with saprolite
− Impurity removal
− MHP/MSP product
• Projects − Ravensthorpe, Australia - EPAL – 38 ktpa 2013
Pros Problems
Utilises saprolite and limonite ore High CAPEX
Problems associated with PAL
Higher complexity
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterite Hydrometallurgy - Heap
Leaching (HL)
• Process − No beneficiation
− Agglomerate all ore
− Put on heap
> Sulfuric acid
> Atmospheric conditions
− No CCDs, impurity removal, Intermediate
product
• Projects: − Çaldağ, Turkey
− Acoje, Philippines
− Murrin Murrin, WA
− Yunnan Yuanjiang Nickel Project, China
− Niquel do Piaui, Brazil
− …
Pros
Low CAPEX/OPEX
Simple
Applicable to low grade
Robust (lim. & sap.)
Problems
Heap permeability
Water management
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Laterite Hydrometallurgy - Bioleaching
• Process − Heap leach or agitated tanks
− Microbes mixed with sucrose/glucose
− Oxalic/citric acid leach
• Projects: − Very early stages, no commercial projects
Selling Points Potential Problems
Tailings, emissions Requires bacteria food source
Doesn’t require mineral acids Residence time
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
In the Works – AL
• Process − Atmospheric leach on limonite
− Saprolite neutralisation
• Projects: − Weda Bay, Indonesia – development
− Oriel resources - exploring
− Heron Resources - exploring
− Metallica Minerals - exploring
Selling Points Potential Problems
Atmospheric conditions Residence time – 12 hours
Less complex Capital still high
Lower energy concsumption Requires correct blend
Iron & acid consumption
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
In the Works - SAL
• Process: − Limonite ore & conc. Sulphuric acid go into pug mill
− Crushed saprolite and water enter the grinding circuit
− Leach
> 1 bar
> 100oC
− CCDs
− Impurity removal
− Intermediate product
• Projects: − Skye Resources, Fenix Project, Guatemala – pilot
Selling Points
Mild conditions
Robust (limonite & saprolite)
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
In The Works – Atmospheric Chloride
Leaching (ACLP)
• Process: − Crushing & grinding
− Leaching
> 1 bar
> 100oC
> Hydrochloric acid
− Regeneration of hydrochloric and magnesite
• Projects: − Jaguar Nickel – piloted 2004
− Jervois mining – explored 2004
− Intec Nickel – piloted with gold 2003
Selling Points
Mild conditions (HCl)
Robust (limonite & saprolite)
Regeneration of reagents
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
• Process: − Crushing & grinding
− Leaching
> 1 bar
> 100-170oC
> Nitric acid
− CCDs
− Impurity removal
− intermediate
• Projects: − Direct nickel piloted in 2013
− Feasibility with PT Antam
In The Works – Atmospheric Nitric Acid
Leaching (DNi)
Selling Points
Mild conditions (NOx)
Robust (limonite & saprolite)
Regeneration of reagents
Hematite by-product
Can use 304/316 SS
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
Final Words
• Shifting process pressures − Feedstock changes
− Environmental legislation
− Nickel demand
• New processes looking at: − Process robustness
− Lower grades
− Environmental impacts
− Energy consumption
− By-product subsidisation
− Lowering CAPEX
− Complexity
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
References
• Butts, C 2007, Nickel Deposits: Laterites and Sulphides,
Presentation for World Nickel Supply Plot
• INSG, July 2013, Sulphide Ore Production Stops Growing, Maquarie
Research
• INSG, July 2013, Laterite Nickel Mine Production Takes Off,
Maquarie Research
• INSG, July 2013, Finished Nickel Production by Ore Type, Maquarie
Research
• INSG, July 2013, Finished Nickel Production by Main Process,
Maquarie Research
• INSG, July 2013, Share of Nickel Production by Process, Maquarie
Research
• D. Houston 1999, Idealised Composite Intrusion Showing Diverse
Stratigraphic Positions of Selected PGE Deposits
• Hatch Associates Limited 2012, Chinese Nickel or Imports by
Country
j ENVIRONMENTAL PROCESSING DESIGN & VERIFICATION PRODUCT INNOVATION PROJECT MANAGEMENT OPERATIONS TRAINING SKILLSHIRE
THANK YOU www.metsengineering.com