AU2007201942B2 - Apparatus and process for making high purity nickel - Google Patents

Abstract

An improved method of reducing a mixed metal oxide composition comprising oxides of nickel, cobalt, copper and iron in a hydrogen atmosphere to produce a mixture of the 5 respective metals, the improvement wherein the atmosphere further comprises water vapour at a concentration, temperature and time to effect selective reduction of the oxides of nickel cobalt and copper relative to the iron oxide to produce the metallic mixture having a reduced ratio of metallic iron relative to metallic nickel, cobalt and copper. Fig.1 H2 0 Nickel Feed 10 H2 ---- Reduction N2 Purge In ----- Metalic Nickel ---- N2 +H 2+H 2 S to Vent H2 S In ----- - Granules:Sulphiding Provision for Purge Gases H2 S Addition oVtCooling Cooling 18 -- Co Make-up Water Out Water In Carbonylation - - - -. Reactor Recycle Blower .. - - -Cooling Residue Cooling :CO + Ni(CO) 4 Water Out Cooling co--l-n- Waterin Residue to Cooling Water In Further Cooling Water In Treatment Water Out Cooling N2+ o2Prge Water Out Decom 20- poser Filter Chamber ~'A Cooling Water Out Cooling 22-- Nickel Powder ---- |Collection Box Cooling Cooling t Water In Water Out N2 Purge out + -- ickel IN2Purge in N2 Purge In Powder +-- -- I N2PPurge Out N 2+ 0 2Purge Out Nickel Powder N2 + 02 Purge In Cooling Cooling Water in Water Out Nickel to Market

Description

P/00/0 I1I Regulation 32 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Apparatus and process for making high purity nickel The following statement is a full description of this invention, including the best method of performing it known to us: 1772 APPARATUS AND PROCESS FOR MAKING HIGH PURITY NICKEL FIELD OF THE INVENTION 5 This invention relates to processes for the production of high purity nickel via carbonylation of impure nickel with carbon monoxide and subsequent decomposition to said high purity nickel; to processes of making said impure nickel, particularly, from compositions comprising mixed metal oxides; and to apparatus of use in said processes. 10 BACKGROUND OF THE INVENTION Nickel carbonyl, Ni(CO) 4 , was first produced by the reaction of metallic nickel with carbon monoxide by Mond in the early part of the 19 th century. Today, one of the major 15 industrial processes for making metallic nickel is based on the production of Ni(CO) 4 and subsequent thermal decomposition thereof to Ni and CO. One known commercial process operates at about 180"C and a CO pressure of about 70 atm. It is known that the CO pressure may be reduced when the reactant nickel is catalytically activated. Activation of the metal has been observed in the presence of mercury (1,2), sulphur in 20 the form of H 2 S (3,4), hydrogen (5,6) or carbon (7). It has been suggested that the high initial rate of formation of Ni(CO) 4 and the subsequent decline to a steady state value is the result of a rapid decrease in the number of activated reaction sites which are produced upon heat treatment of the sample (6,8,9). A study of surface changes during carbonyl synthesis suggests that the maximum rate is associated with fundamental changes in the defect 25 structure. All of the above methods use catalytic activation of nickel in the presence of CO. Canadian Patent No. 822,016 - The International Nickel Company of Canada, published September 2, 1969, discloses a high pressure carbonylation process for particular use with smelter nickel intermediates high in copper and iron. Methods of reducing mixed metal oxide compositions comprising oxides of nickel, 30 cobalt, copper and iron with hydrogen to produce the respective metals for subsequent nickel carbonylation in the presence of 112S and subsequent decomposition of the nickel carbonyl to metallic nickel in powder or substrate form are known.

'A

However, there remains a need for an improved process of preparing high purity nickel, particularly, nickel powder having acceptable levels of sulphur and metallic impurities, e.g. Co, Cu and Fe. Reference to any prior art in the specification is not, and should not be taken as, an 5 acknowledgment or any form of suggestion that this prior art forms part of the common general knowledge in Australia or any other jurisdiction or that this prior art could reasonably be expected to be ascertained, understood and regarded as relevant by a person skilled in the art. As used herein, except where the context requires otherwise the term 'comprise' and variations of the term, such as 'comprising', 'comprises' and 'comprised', are not intended to 10 exclude other additives, components, integers or steps. PUBLICATIONS 1. Morton J.R., Preston K.F. J Chem. Phys., 81, 56, (1984). 2. Morton J.R., Preston K.F. Inorg. Chem., 24, 3317, (1985). 3. Mercer D.L; Inco Ltd. (Can. 1038169 [1975/78]. 15 4. Schafer H.Z. Anorg. Allg. Chem. 493, 17 (1982). 5. Job R. J. Chem. Educ. 56, 556 (1979). 6. Mazurek H., Mehta R.S., Dresselhaus M.S., Dresselhaus G., Zeiger H.J. Surf Sci. 118, 530 (1982). 7. Korenev AN., Shvartsman R.A., Mnukhin A.S., Tsvetn. Met. 1979 Noll, pp.37. 20 8. Mehta R.S., Dresselhaus M.S., Dresselhaus G., Zeiger H.J. Surf Sci. 78, L681 (1978). 9. Greiner G., Manzel D. J. Catal. 77 382 (1982). SUMMARY OF THE INVENTION It is an aspect of the present invention to provide a method for producing an improved quality nickel, particularly in the form of a powder. 25 It is a further aspect to provide a method of selectively reducing the ratio of metallic iron relative to metallic Ni, Cu and Co from the ratio of said metals in the: form of their respective oxides in a starting composition comprising said oxides. 2 It is a further aspect to provide an improved method of producing activated nickel for subsequent carbonylation from a metallic admixture comprising metallic nickel, cobalt, copper and iron. It is a further aspect to provide metallic nickel when made by said processes. 5 It is a further aspect to provide nickel carbonyl from the reaction of said metallic nickel with carbon monoxide and subsequent decomposition of said nickel carbonyl to metallic nickel, particularly in the fonn of nickel powder. 2a It is a further aspect to provide apparatus of use in the aforesaid processes. Accordingly, in one aspect, the invention provides an improved method of reducing a mixed metal oxide composition comprising oxides of nickel, cobalt, copper and iron in a hydrogen atmosphere to produce a mixture of the respective metals, the improvement 5 wherein said atmosphere further comprises water vapour at a concentration, temperature and time to effect selective reduction of said oxides of nickel cobalt and copper relative to said iron oxide to produce said metallic mixture having a reduced ratio of metallic iron relative to metallic nickel, cobalt and copper. The process is of value where the mixed metal oxide composition has an iron oxide 10 content preferably of less than 4% w/w, more preferably less than 2% w/w, as found for example, in the mixed oxide composition obtained by the roasting of nickel matte smelter product, generally known as oxide calcine. The hydrogen reduction process is, preferably, carried out at a temperature selected from about 350'C to about 550'C, preferably, about 500 0 C. 15 The water vapour content in the hydrogen gas reductant atmosphere is, preferably, but not limited to, ranges from 10% to 50% by volume, and more preferably 30% v/v H 2 0. The reductant atmosphere may further comprise carbon monoxide and carbon dioxide, particularly. carbon monoxide and hydrogen contained in so-called "producer gas". The atmosphere preferably comprises the hydrogen and water in a ratio of 10:1 to 1:1 20 hydrogen to water, preferably, 3:1 H 2

:H

2 0, more preferably 10-50% v/v H 2 0, and still more preferably, 25-35% v/v H 2 0. The carbon dioxide content in a carbon monoxide containing reducing gas should preferably be, but not limited to, C0 2 /CO ratios by volume ranging between 1/2 and 5/1 and more preferably 2/1. 25 The resultant metallic mixture product according to the invention, when made by a process as hereinabove defined, is of particular value when used in a pre-sulphiding process as hereinafter defined. In a further aspect, the invention provides a method of producing an activated metallic nickel from a metallic nickel for subsequent reaction with carbon monoxide, said method 30 comprising pre-sulphiding said metallic nickel with hydrogen sulphicle at a pressure selected from I to 3 atmospheres (100 to 300 kPa) and a temperature selected from 20 - 1500 for an effective activation period of time. 3 In this specification and claims pressures may be considered to be partial pressures when an inert gas is also present. In a preferred aspect, the metallic nickel is in admixture with one or more metals selected from cobalt, copper and iron wherein admixture is treated with said hydrogen 5 sulphide to effect production of one or more sulphides, selected from copper sulphide, cobalt sulphide and iron sulphide. In one embodiment, the aforesaid admixture is a metallic mixture product obtained by the reduction with gaseous 112/H20 as hereinabove defined. Preferably, the pre-sulphiding temperature is selected from 100-120'C and the 10 pressure is selected from I to 2 atmospheres (100 to 200 kPa). Thus, in a further aspect, the invention provides an activated nickel when made by a pre-sulphiding method as hereinabove defined. In a further aspect, the invention provides producing said purified nickel in the form of a powder. 15 In a further aspect, the invention provides apparatus for the production of high quality nickel from an impure nickel source composition comprising oxides of metals selected from the group consisting of nickel, iron, cobalt and copper, said apparatus comprising (i) a reducing chamber for containing said composition; (ii) means for heating said composition to a temperature selected from 350'C 20 650'C; (iii) means for providing said reducing chamber with a reducing gaseous atmosphere comprising hydrogen and water to operably produce a first admixture comprising metals selected from the group consisting of nickel, cobalt and copper; (iv) non-carbonylation pre-sulphiding means for treating said first admixture with 25 hydrogen sulphide at a temperature selected from 20'-150'c to produce a second admixture comprising metallic nickel and metallic sulphides selected from copper and cobalt; (v) carbonylation means for effecting carbonylation of said second admixture to produce nickel carbonyl; and (vi) decomposition means for effecting decomposition of said nickel carbonyl to 30 said high purity nickel. Thus, the present invention provides, principally, the production of refined nickel powders, while utilizing a most effective way of achieving sulphide activation of a wide 4 variety of metallic nickel starting materials, particularly, impure metallic nickel feed materials containing substantial quantities of copper, iron and cobalt, prior to charging a carbonylation reactor at essentially atmospheric pressure, for the production of nickel carbonyl gas of desired strength, without the production of any liquid carbonyls, and 5 subsequent decomposition of the carbonyl gas to yield nickel powders with predetermined, specific physical and chemical properties. The present invention provides for the carbonylation reaction to be carried out at essentially atmospheric (1OOkPa) pressure, and, accordingly, large scale commercial operations can readily be engineered for continuous operation. 10 The nickel activation step using H 2 S, herein termed "pre-sulphiding" as hereinabove defined at relatively low temperatures, is effected most preferably in an oxygen-free, preferably, nitrogen atmosphere, preferably at a slightly-above atmosphere pressure (1 OOkPa) at room temperature or preferably at slightly above room temperature, depicted as T 2 in Figure 1 and data presented in Table 2. Such pre-sulphiding can be accomplished in the feed 15 bins, or in the transfer conveyor usually located between the reduction reactor and the feed bins. Alternatively, a portion of the sulphiding can be effectively accomplished in the carbonylation reactor per se, for example, by a continuous controlled addition of H 2 S to the incoming CO gas. The apparatus further comprises apparatus for the production of high purity nickel 20 from a metallic nickel source, comprising (a) non-carbonylation pre-sulphiding means for treating said nickel source with hydrogen sulphide at a temperature selected from 20'C to 150'C to produce activated nickel; (b) carbonylation means for effecting carbonylation of said activated nickel to produce nickel carbonyl; and 25 (c) decomposition means for effecting decomposition of said nickel carbonyl to said high purity nickel. Yet further, the apparatus further comprises apparatus for the production of high quality nickel from an impure nickel source composition comprising oxides of metals and selected from the group consisting of nickel, iron, cobalt and copper, said apparatus 30 comprising (i) a reducing chamber for containing said composition; 5 (ii) means for heating said composition to a temperature selected from 350'C 650'C; (iii) means for providing said reducing chamber with a reducing gaseous atmosphere comprising hydrogen and water to operably produce a first admixture comprising 5 metals selected from the group consisting of nickel, cobalt and copper; (iv) non-carbonylation pre-sulphiding means for treating said first admixture with hydrogen sulphide at a temperature selected from 20 ' 150%c to produce a second admixture comprising metallic nickel and metallic sulphides selected from copper and cobalt; (v) carbonylation means for effecting carbonylation of said second admixture to 10 produce nickel carbonyl; and (vi) decomposition means for effecting decomposition of said nickel carbonyl to said high purity nickel. By the term "activation" as used in this specification, is meant the process of producing activated nickel which has the form to react expeditiously with CO at about 25 15 50'C and 1-2 atmospheres (100 to 200kPa) pressure, to produce nickel carbonyl. BRIEF DESCRIPTION OF THE DRAWINGS In order that the invention may be better understood, preferred embodiments will now !0 be described by way of example only, with reference to the accompanying drawings, wherein Fig. 1 is a diagrammatic representation of apparatus and process for the production of high purity nickel from impure nickel, according to the invention; Fig. 2 is a graph of TGA Tests that show the effect of reduction temperature on sulphiding, at I OOkPa, 50*C of FBR Calcine (Sample E); 25 Fig. 3 is a graph of TGA Tests that show the carbonylation of impure nickel matte calcine, material "E" at atmospheric (IOOkPa) pressure and 50'C, after reduction in hydrogen and subsequent pre-sulphiding to various activation levels; Fig. 4 is a graph of TGA Tests that show the carbonylation of impure nickel matte calcine, Material "F" at atmospheric (IOOkPa) pressure and 50'C, after reduction in hydrogen 30 and subsequent pre-sulphiding to various sulphur activation levels; 6 Fig. 5 is a graph of TGA Tests that show the carbonylation of impure nickel matte calcine, Material "F" at atmospheric (IOOkPa) pressure and 50'C, after reduction in 30% v/v

H

2 0-70% v/v H 2 at 500*C; and after pre-sulphiding at various temperatures to various 5 sulphur activation levels; Fig. 6 is a graph of carbonylation of nickel-cobalt hydroxide material under various reduction and carbonylation conditions, but without sulphiding; and Fig. 7 is a graph of carbonylation of nickel-cobalt hydroxide material under various reduction and carbonylation conditions, under varying degrees of pre-sulphiding activation. 10 DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Fig. 1 shows apparatus and process constituents for making nickel powder from an impure nickel feed, which apparatus and process involve known steps of nickel feed 15 preparation, carbonylation of nickel with carbon monoxide and subsequent decomposition of resultant nickel carbonyl to metallic nickel. In the apparatus and process of the present invention, a nickel feed comprising oxides of Ni, Fe, Cu and Co are reduced in an atmosphere of 30% v/v H 2 0 - 70% v/v H 2 at a temperature of about 500'C to produce a composition of metals of Ni, Cu and Co, in chamber 20 10. This composition , cooled to room temperature, is fed to a pre-sulphiding chamber 12 by feed conduit 14 and treated with H 2 S at a temperature of 20-60'C and slightly above atmospheric pressure, to effect selective sulphidization of Co and Cu over Ni, while activating the nickel to an appreciable degree. This resultant activated nickel is fed to 25 carbonylation reactor 16 via feed conduit 18. Subsequent carbonylation to nickel carbonyl and decomposition thereof in chamber 20 results in nickel powder being collected in box 22. Preferred temperatures and gas and water circulation steps are shown in Fig. 1. With reference to the Figures, the notations shown therein denote the following: 30 7 In Figure 2 * Reduction time in hydrogen, Hours x Sulphiding Time for 6% wt gain, Hours - after reduction in pure hydrogen 5 M Reduction time in 30%H20-70%H2 gas mixture, Hours LI Sulphiding Time for 6% wt gain, Hours - after reduction in 30% H20-70% H2 gas mixture In Figure 3 10 - - - E21 - sample weight = 5.3g, reduction at 425 oC, 1% sulphur, (30 oC Carbonylation) - - - E18 - sample weight = 5.Sg, reduction at 425 oC, 2% sulphur E19 - Sample weight = 5.5g, reduction at 425 oC, 4% sulphur E14 - Sample weight = 5.5g,reduction at 425 oC, 6% sulphur -- E16 - sample weight = 5.6g, reduction at 425 oC, 6% sulphur ---- E17 - sample weight = 1.6g, reduction at 425 oC, 6% sulphur 15 E20 - sample weight 20g, reduction at 425 oC, 6% sulphur E22 - sample weight = 5.5g,reduction at 500 oC, 2% sulphur E15 - sample weight =5.6g, reduction at 500 oC, 6% sulphur E23 - sample weight= 2.6g, reduction at 500 oC, 6% sulphur In Figure 4 20 - F4 - reduction at 425 oC, 2% sulphur - F5 - reduction at 425 oC, 4.5% sulphur - F6 - reduction at 425 oC, 6% sulphur - F9 - reduction at 500 oC, 4% sulphur 25 FIO - reduction at 500oC, 4.5% sulphur - F7 - reduction at 500 oC, 4.5% sulphur F8 - reduction at 500 oC, 6% sulphur 30 8 In Figure 5 F11 - 2 wt % S at 50 OC atmospheric - F12-4.5wt%Sat5OoC 100kPa 5 - - - F13 - 3 wt % S at 100 oC atmospheric F14 - 3 wt % S at 120 oC atmospheric F15 - 3 wt % S at 135 oC atmospheric -F16 - 3 wt % S at 150 oC atmospheric 10 In Figure 6 G1- Reduction in H2 at 300 oC, Carbonylation 30 oC 10OOkPa - G2- Reduction in H2 at 350 oC, Carbonylation 30 oC 1 OOOkPa - - - G3- Reduction in H2 at 400 oC, Carbonylation 50 oC OkPa - G4- Reduction in H2 at 400 oC, Carbonylation 30 oC 1OOkPa -G5- Reduction in H2 at 400 oC, Carbonylation 30 oC 700kPa - G6- Reduction in H2 at 400 oC, Carbonylation 50 oC 700kPa -- G7- Reduction in H2 at 400 oC, Carbonylation 30 oC 1000kPa 15 -G8- Reduction in H2 at 400 oC, Carbonylation 50 oC 1OOkPa - - G9- Reduction in H2 at 400 oC, Carbonylation 85 oC 1 OOkPa - G13- Reduction in H2 at 500 oC, Carbonylation 30 oC OkPa -- G18- Reduction in H2 at 500 oC, Carbonylation 50 oC OkPa G19- Reduction in H2 at 500 oC, Carbonylation 30 oC 100OkPa -G20- Reduction in H2 at 500 oC, Carbonylation 85 oC 10OOkPa In Figure 7 20 G14-Reduction in H2 at 450 oC, 0% wt. S, Carbonylation 50 oC OkPa - G15-Reduction in H2 at 450 oC, 1.0% wt. S, Carbonylation 50 oC OkPa - G16-Reduction in H2 at 450 oC, 2.5% wt. S, Carbonylation 50 oC OkPa - - G17-Reduction in H2 at 450 oC, 5% wt. S, Carbonylation 50 oC OkPa G10-Reduction in H2 at 400 oC, 0.60% wt. S, Carbonylation 50 oC 700kPa Gl-Reduction in H2 at 400 oC, 2.00% wt. S, Carbonylation 50 oC l0kPa G12-Reduction in H2 at 400 oC, 7.00% wt. S, Carbonylation 50 oC 100kPa G25-Reduction in H2 at 400 oC, 0% wt. S, Carbonylation 50 oC 1OOkPa G26-Reduction in H2 at 400 oC, 2.00% wt. S, Carbonylation 50 oC 100kPa 25 G27-Reduction in H2 at 400 oC, 2.00% wt. S, Carbonylation 50 oC 1OOkPa G28-Reduction in H2 at 400 oC, Carbonylation 50 oC 1OOkPa CO-8% H2S G29-Reduction in H2 at 400 oC, Carbonylation 50 oC 1OOkPa CO-0.02% H2S - - - G30-Reduction in H2 at 400 oC, 3 % wt. S. Carbonylation 50 oC 100kPa Various nickel containing materials, their sources and compositions are shown in Table 1, by way of example only. The present invention is applicable to a wide variety of 30 similar compositions or the treatment of relatively pure metallic nickel. Nickel-containing feed can be provided from various sources and in several different chemical and physical forms, having the nickel as metal, sulphide, oxide, hydroxide, or 9 carbonate. Thus, the feed preparation step is tailored to the nature of the source nickel. For example, in the case of nickel matte emanating from smelters, the nickel usually contains 20 or more percent w/w of sulphur, and usually contain other metals, such as copper, cobalt, iron and impurities, such as silicate materials, and, often, will also contain minor, but valuable 5 quantities of precious metals. In preparing such matte in the practise of the present invention, it is preferable that the matte be in granular form before being passed on to a roasting step at elevated temperatures that could be as high as 11 50'C. This eliminates sulphur and converts all of the base metals to oxides. The resulting oxide granules are passed to a reduction step, normally at 10 temperatures between 350*C - 650'C to provide the nickel in granular metallic form. If the nickel source is a hydroxide or carbonate, a single heating-reduction step is adequate to provide the nickel as metallic fines. These metallic nickel forms are acceptable for carbonylation in the practise of the present invention. Table 2 15 Pre-Sulphiding of High Grade Nickel Granules (TGA Tests) Sample % Mesh Sulphiding Pressure of Sulphiding Sulphur pick-up ID Nickel Size Temperature H 2 S, Time, Hours by the nickel, *C psi wt. % Al 99+ -100 50 30 7.5 0.65 A2 99+ -100 25 45 7.5 0.51 A3 99+ -100 25 30 7.5 0.25 BI 99+ -100 25 30 7.5 0.19 B2 99+ -100 25 45 7.5 0.20 B3 99+ -100 50 45 7.5 0.24 Cl 95+ -48 25 30 7.5 0.30 C2 95+ -48 25 45 7.5 0.45 C3 95+ -48 50 30 7.5 0.67 C4 95+ -48 50 45 7.5 0.98 20 10 Table 1 Materials Identification Sample Materials Tested Composition, wt. % ID A Nickel Granules, Australian Commercial 99%Ni, 0.11% Co, 0.03% Fe, Source: final product from a leaching Balance oxygen operation B Nickel Granules, Canadian Commercial 99%Ni, 0.15% Co, 0.034 Fe, Source: final product from a leaching Balance oxygen operation C Nickel Granules, Japanese Commercial 95.5% Ni, 0.20% Cu, 1.4% Co, Source: Nickel matte granules fluid bed 0.60% Fe, Balance oxygen roasted and subsequently fluid bed reduced D Sinter 75 nickel oxide, Japanese 77%Ni, 0.65% Cu, 1.11% Co, Commercial Source: nickel matte granules 0.38% Fe, Balance oxygen fluid bed roasted to oxide E Calcine Granules: produced by fluid bed 59%Ni, 16% Cu, 0.92% Co, roasting in a pilot plant operation, of impure 4.07% Fe, 0.05% S, Balance matte granules, high in copper and iron oxygen coming from a Chinese commercial smelting operation F Calcine Granules: produced by laboratory 62%Ni, 12% Cu, 0.94% Co, roasting, of impure matte granules, high in 2.1% Fe, 0.0 1% S, Balance copper but lower in iron than "E", from the oxygen same Chinese commercial smelting operation G Nickel hydroxide intermediate material: 32%Ni, 4.46%Co, 0.08%Fe, recovered by lime precipitation of liquor 5.55%Mn, 0.53%Cr, 0.70%Zn obtained by acid leaching of nickel laterite ore (b) 13.4%Ni, 0.58%Co, 0.35%Fe, 0.78%Mn, 0.06%Zn (c) 11.5%Ni, 0.94%Co, 0.55%Fe, 0.36%Mn, 0.10%Zn 5 1 1 The nickel granular or fine feed, that may already be activated by reaction with H 2 S, is fed to a carbonylation reactor chamber wherein the exothermic carbonylation reaction of nickel with carbon monoxide is carried out. The reactor, for example, may be either a packed 5 bed or a moving bed type, wherein moving bed type is either a rotary bed or a fluid bed. The reactor is provided with cooling means whereby the excess heat generated by the reaction is effectively removed. Carbonylation was found to proceed at reasonable/practical rates at temperatures as low as 38*C and as high as 80*C when operating at essentially atmospheric pressure, or just 10 modestly above atmospheric pressure, with temperatures in the narrow range of 50'C to 60*C proving to be optimum in many cases, as seen in Table 3, hereinafter. Nickel carbonyl-laden carbon monoxide leaving the reactor chamber, after passing through a filter, held essentially at reactor temperature (35-60'C), is fed to a decomposer chamber through a cooled feed nozzle to prevent decomposition occuring in the nozzle as gas [5 is introduced into the decomposer chamber in which the temperature, T 8 , (250-450*C) is normally set at temperatures above 250'C. At the same time, the feed nozzle is not below about 45*C to avoid production of undesirable liquid nickel carbonyl. Accordingly, water cooling of the feed nozzle is closely controlled to yield a cooling outlet temperature, T 7 , between 40 - 60*C. !0 Figure 1 illustrates a preferred process and apparatus of use in the practise of the invention wherein temperatures and material flows are shown. In the aforesaid process, over 99% of the nickel carbonyl is decomposed and collected in the collection box. EXAMPLES 25 Example 1: Sulphiding and Carbonylation of Nickel Metallic Granules Metallic nickel granules containing 99+% Ni essentially free of any sulphur, and of minus 100 mesh size, Test "A5", were charged to an oxygen-free reactor chamber that had been purged with nitrogen gas, and a first quantity of hydrogen sulphide was introduced into the chamber at a pressure of 200kPa. The chamber was sealed off and the nickel was held at 30 this slightly elevated pressure for 8 hours at room temperature of around 25'C. The resulting nickel granules analyzed for 0. 11 w/w %S. 12 Some 2.8 kilograms of these sulphided granules were charged to a rotary kiln-type oxygen-free moving bed mini-pilot plant reactor which had been purged with nitrogen gas. A continuous stream of carbon monoxide of about 8 times in excess of stochiometric requirements and a second small quantity of hydrogen sulphide was introduced to the 5 chamber, at essentially atmospheric pressure, while the temperature in the reactor was held at about 40'C. The gases exiting the reactor chamber contained over 10% by volume of nickel carbonyl during the first 6 hours, which gradually dropped to around 8% v/v after 24 hours. The exit gas contains about 2% when the reaction was stopped before the reaction had reached completion. The carbon monoxide plus nickel carbonyl product gases were passed 10 directly to a mini-pilot plant powder decomposer (described in Example 2 hereinafter), that was controlled at a decomposition temperature of around 400'C. The nickel powder collection box was maintained at a temperature above 170'C. After stopping the flow of carbon monoxide to the carbonylation reactor, the system was allowed to cool down while being purged with nitrogen gas, and the powder was cooled to room temperature of around 15 25*C. Some 72% of the nickel in the metallic granules had been converted to nickel powder of 0.06 w/w % S with a density of 1.12 g/cc. In a related series of tests in a Thermo Gravimetric Analyzer (TGA), sulphiding of metallic nickel granules demonstrated sulphur pick-up efficiency at low temperatures. As seen in Table 2, the "B" sourced nickel granules were less active, i.e., they sulphided at 20 considerably slower rates than either the "A" or "C" nickel granules. Subsequently, in each case the three sources of nickel granules after sulphiding, were carbonylated in mini-pilot plant reactors, either in a packed bed reactor or in a rotary kiln reactor. The results are summarized in Table 3. Again, the "B" sourced nickel granules reacted more slowly with the carbon monoxide to form nickel carbonyl than the other two 25 sourced nickel materials. In test C5, impure 95.5%Ni granules produced from granulated nickel matte that had been roasted in a commercial fluid bed reactor at I1 00*C and then reduced in a commercial fluid bed reducer with hydrogen at around 800C, was first sulphided at 60*C for 6 hours in a nitrogen atmosphere with a H 2 S gauge pressure of 300kPa. This product was subsequently 30 charged in a packed bed and subjected to reaction with carbon monoxide at essentially atmospheric pressure. Additional H 2 S had been added to the carbon monoxide 13 inlet gas to the reactor representing, in total, a pick-up of sulphur of 1.7 w/w % of the nickel charge, and the nickel carbonyl gas strength, as measured by a UV analyzer, averaged around 6 v/v % for most of the reaction period. 5 The product gases from the reactor were passed through the decomposer described in Example 2. The nickel powder product had a bulk density of 0.55g/cc, but an elevated, undesirable sulphur content of 1.29 w/w %. The residue analyzed 3.38% S. Example 2: Decomposition of Nickel Carbonyl and Collection of the Nickel Powders 10 In a series of tests, a carbon monoxide gas stream containing varying concentrations of nickel carbonyl gas, was passed through a mini-pilot plant decomposer reactor chamber, 12 cm in diameter and 75 cm long held at various temperatures and fed at various flow rates to produce nickel powders, and the nickel powders were collected in a collection box 30 cm in diameter and 30 cm long held at various temperatures. 15 20 25 30 14 u ~CD 6. kn C e1 CD C) 00kr cio o- 6. - \o _* Yu cn C) 00C) 0 0 00 0>C 00 e0 000~ C'~-0 e~CSI Cl q (Z \ \r kn nD 6. -0 - 0 0- k II 0 V L0 0 v z 00 00 00 00 Cl 00 0 ~~ 66606 CL 0- 0 kn'~0r Lr) N 0n kn V- 0 00 <0NN %.o C>C- 000 co 0000000IT00 00-0 0 U00 m~'I 'n 'T 00 -000- 00\0 0 00 - 0 +- -0 - '. + Z~ Z .0 < u 0 0 o. ~ Q 00 00 'N 0 0+ Table 4 Decomposition of Nickel Carbonyl and Collection of the Nickel Powder Decomposer Nickel Nickel Collection Box Density of Temperature Carbonyl Carbonyl Temperature Powder Remarks *C Feed Rate Strength, 0 C g/cc g/min % Ni (CO) 4 by volume 390* 8.5 16.5 RT (-25') N/A Liquid carbonyl collected in the box and agglomerate d much of the powder. 355 10.8 21.2 170 1.5 No liquid carbonyl 380 6.6 14.1 150 1.2 No liquid I carbonyl 360 10.0 5.7 120 1.1 No liquid I__ I I carbonyl A smaller mini-pilot plant decomposer was employed in this first test: 5 cm in diameter and 60 cm long. 5 The results of these tests, summarized in Table 4, clearly demonstrated the importance of controlling the temperature in the powder collection box in order to prevent re-carbonylation of the product nickel powder. By holding the temperature above 120'C the production of liquid nickel carbonyl in the collection box was avoided, while 99+% of the gaseous nickel carbonyl was decomposed yielding nickel 10 powders and a carbon monoxide suitable for recycle to the reactor chamber. Example 3: Treatment of an impure Nickel Matte Feed material A laboratory-sized sample of nickel matte analyzing 59.8% Ni, 10.5% Cu, 0.9% Co, 3.2% Fe and 21.0% S by weight, was roasted at temperatures starting at around 650'C and gradually increased to 1050'C for essentially complete elimination 15 of the sulphide sulphur. The resulting oxide calcine was subsequently reduced with hydrogen at a temperature of 450*C. A 250 gram sample of the reduced material was charged to a packed bed reactor and reacted with carbon monoxide gas at 60*C, without any sulphiding pre-activation, at 50*C, but with excess activating hydrogen sulphide amounting to a total of some 6.5% by weight of the metallic charge added to 20 the carbon monoxide. The reactor product gases were fed directly to a heated tube decomposer which recovered the nickel in solid plated form. Without the pre activation of the metallic charge, the gas strength in the reactor product gases was 16 very low at about 2 v/v % nickel carbonyl, while the nickel product plate was high in sulphur at 2.2 w/w % as a result of excessive H 2 S presence in the CO. This test shows that while a measure of pre-activation of the metallic charge is useful, the amount of activating H 2 S gas added to the carbon monoxide during carbonylation should be very 5 much reduced. Example 4: Treatment of an impure high-nickel Nickel Oxide Feed material 500 kilograms, of granular nickel oxide containing 77 w/w % Ni, containing minor quantities of cobalt, iron and sulphur was fed to a pilot plant rotary kiln reactor of about 46 cm in diameter, a heating zone 200 cm long, and a cooling zone, at a feed 10 rate of about 1 kilogram per hour. The feed was reduced with hydrogen gas at a temperature of 425*C in a continuous manner with retention in the hot reducing zone of about 2 hours. The nickel oxide was 90% reduced. 300 grams of this 90% reduced material, was further reduced to completion in a small laboratory packed bed reactor at 425'C, some pre-sulphiding with H 2 S at 50*C was carried out, and the sample was 15 then subjected to atmospheric carbonylation at 50*C. Continuous activation of the nickel was effected by continuous addition of hydrogen sulphide with the carbon monoxide. After 30 hours, some 90% of the nickel was extracted. However, as an excessive amount of activation sulphur had been added totalling some 0.73% of the metallized feed, the product nickel powder had an undesirable elevated content of 20 sulphur of 0.52%. In a second test, more sulphur was added during pre-sulphiding and less hydrogen sulphide was added to the carbon monoxide incoming gas, but also only after some 10 hours of initial carbonylation. The metal product powder had an acceptable low-sulphur content of 0.08 w/w %, as seen in Table 5. However, the 25 degree of nickel extraction after 28 hours had dropped to 60%. 30 17 CCD M u Q .2 . 0 tu C 00 CL u- 0 Gq 00 0 0 4-' C C>C 00 00 00 C) cu U C u 00 0~ u ~C ~ E~ o +) 18~ j~ Example 5: Processing of impure Nickel Matte for the production of refined carbonyl Nickel Powder, in mini-pilot plant reactor In a series of tests, a granular nickel matte containing substantial quantities of 5 copper and iron impurities, obtained from a commercial nickel smelter was roasted in a pilot plant fluid bed roaster of 20cm diameter, at temperatures between 1070C and 1 100*C. The resulting calcine, material "E", in Table 1, contained 59%Ni, 16%Cu, 0.9%Co, 4%Fe and less than 0.1%S. This calcine was subsequently reduced with hydrogen at temperatures between 400'C and 500'C, subsequently sulphided with 10 H 2 S under varying conditions, and reacted with carbon monoxide at 50*C to 55C and at essentially atmospheric pressure, i.e., below 1OOkPa, and in most cases below about 35kPa in a mini-pilot plant carbonylation reactors. The gases exiting the reactors containing nickel carbonyl were directed to the mini-pilot plant powder decomposer held at 400*C (except in Test E5). The nickel and iron extractions, sulphur analyses 15 of feed, product and residue, and density of product powders are summarized in Table 6. In all cases, carbonylation/extractions were still proceeding when the tests were stopped. In test E5, all of the activation sulphur was added continuously as H 2 S to the incoming CO gas stream, which resulted in high pick-up of sulphur and high nickel 20 extraction. However, a considerable proportion of the added sulphur ended up in the product nickel plate (2.2% w/w S). In test E6, activation sulphur was added to the reduced metal by reacting a gaseous mixture of 90v/v% H 2 /1Ov/v% SO 2 , with the metal prior to carbonylation; and further addition of H 2 S gas was added during carbonylation. It is seen in Table 6 25 that nickel extractions improved with the higher level of sulphur additions, and that pre-sulphiding with no subsequent addition of H 2 S to the CO stream yielded nickel powder low in sulphur content. It is believed that the higher sulphur levels tie up more of the copper impurity thereby "freeing" more of the nickel for reaction with the carbon monoxide. Furthermore, it is also believed that reduction at the higher 30 temperature of 500C suppresses, to some degree, subsequent extraction of the iron impurity. 19 CI)C) 00 0 1 CN CN - 00 0 0 00 V- Cl r r- m l CD C; C c> C.) m0 CD~(N Cl 0 u 0 0 C)N 00 \0 0 0 0 C 00 '. 0 - 0 Cu CE - r- C) C> - re C o 00 00 'iN Q - _4_ 0 .0. 00~j 00 It kn N 000 C> 0 0/0 0 C) ~ ~ ~ ~ ~ ~ I C) k-V n C)C > C 0~ 0 uJ 0 0 000 0 00 000 00o 00 u 0 0 ~ Q '/N C C=) CI) +0 0 0 000 0 0 CCO Cu 3 0. ~E lCl CD Cl "u U Cl kf)kf Cl) 0 g 0 + 0 a CI Example 6: TGA Tests* related to the processing of impure Nickel Matte products Comprehensive series of TGA (Thermo Gravimetric Analyzer) tests were carried out on impure nickel oxide/calcine granules to study the effects of reduction temperature, and of varying the degree of low-temperature pre-sulphiding on subsequent nickel and iron 5 carbonylation extractions. Material "E", similar to that of Example 5, was the source of feed for these tests. Another series of tests was carried out on material "F" as the feed. Reduction temperatures were varied, pure hydrogen was employed for reduction, in one series on Material "E", while addition of H 2 0 to the hydrogen gas in another test series on material "E" was carried out. 10 Pre-sulphiding was effected in all cases at 500 C, and carbonylation was carried out at atmospheric (100kPa) pressure and 500 C, except in tests E16 and E21 where carbonylation was carried out at 300 C. The results with material "E" are summarized in Tables 7 and 8, and in Figures 2 and 3. It can be seen that nickel carbonyl extractions were higher with the nickel oxide/calcine 15 reduced at the lower temperature of 425' C as compared to 5000 C. Also, nickel extractions were higher at the higher sulphur levels, for example, with the 2%w/wS yielding a 74% extraction and 4.5%w/wS yielding 88% for material "F" in the same time period, (Test F4 versus F5). Tests E17, E20 and E23, which yielded nickel extractions as high as 91%, are characterized by smaller test samples. On the other hand, higher reduction temperature 20 coupled with the higher sulphur addition, E23, suppressed iron extraction while yielding a high nickel extraction. In comparing iron extractions, there is a notable drop to about one half, between the higher-iron feed material "E" and the lower-iron feed material "F". The most surprising results with beneficial implications for commercial applications, are evident in tests Fl Ito F16, in which iron extraction is virtually completely suppressed by 25 carrying out the preparatory reduction step in a hydrogen gas containing H 2 0 vapour. Also some surprising results with important processing implications are depicted in Figure 2. When the reduction of the nickel oxide/calcine was carried out in pure hydrogen, the pre-sulphiding operation was distinctly slowed down as the reduction temperature was increased. However, when the reduction was carried out with hydrogen gas containing H 2 0, 30 subsequent sulphiding was extremely rapid. It should be noted that the TGA Tests provide "relative" results as distinct from "absolute" results, particularly with regard to rates of reaction (i.e. reaction times) which rates 21 depend to a large extent on the equipment configuration, on the selection of solid sample sizes and on gas flow rates. Example 7: TGA Tests related to the processing of impure Nickel Matte of the lower iron content, Material "F" 5 Another comprehensive series of TGA tests was carried out on the impure nickel oxide/calcine granules Material "F", in which a range of weaker hydrogen gases diluted with

H

2 0, were employed for reduction, and in which the low-temperature activation sulphur levels were varied. Material "F", Table 1, an impure matte calcine analyzing 62%Ni, 12%Cu, 2%Fe and 10 0.01%S, was produced in the laboratory by tray roasting of granulated matte feed at temperature up to 10500 C. While reduction temperatures gas strengths and sulphiding additions with H 2 S were varied, except in one test wherein sulphiding with elemental sulphur was attempted, the conditions for carbonylation at atmospheric (10OkPa) pressure and 500 C, were maintained constant. The results are summarized in Tables 9 and 10 and depicted in 15 Figures 4 and 5. It is seen that the lower reduction temperature of 4250 C yielded higher nickel and iron extractions than at the higher reduction temperatures, in the same period of carbonylation, as was already demonstrated in earlier examples. Optimum level of activation sulphur is around 4.5w/w% S for material "F". Lowering the gas strength of reduction by the 20 presence of H 2 0 slowed the nickel reaction rate modestly. Most significantly, iron extraction was drastically lowered by the employment of the humid gaseous mixture of 30% v/v H 2 0 / 70% v/v H 2 0 during reduction. Furthermore, results summarized in Table 10 show that increasing sulphur above the 2% level helped suppress iron extraction, and that pre sulphiding with H 2 S gas at temperatures between 700 C and 1350 C, and, preferably, 25 between 1000 C and 120* C, yielded the best nickel extractions. The tests carried out in Example 7, demonstrated that nickel products low in iron can be produced from impure matte calcine containing some 2 w/w % iron as compared with the impure matte calcine treated in Example 6, which contained the higher levels of iron. Comparative results are summarized in Table 10 of treating 2w/w%Fe materials with those of 30 Table 8, of treating 4w/w%Fe material, wherein the reduction were carried out with gases 0% v/v H 2 0/ 70% v/v H 2 . Table 9 also demonstrated that pre-sulphiding by addition of elemental sulphur was not satisfactory. 22 ~ ~C) C> C) C) C) ':- '. C ) C) (N C) C> knC)O Q' N nO 00 kr -C mN Ck ~ ) C r) m 0 w 00- rl (N - - 1- \ - 00 110( z ~ C) C) C:) C) (C) C) C) CD C) C:) kr m k ~ r) kr) CT) Cr') (') CC) Cr 0 C)~ CD C) C> C) C) C) C) CD C) C) C) C .C) C' C? C! C) C) -E ) ) C) C) C) C) C) ) ~ i) ) C) C) C>) CD' C) C) CD) D CD ) C C C) CD CD C) CD C) V" ') C') C') V') C:) C) Ci) CS C C CCC) CC) ol ' J- C5 C5 *U) \0c V) C - -' ~In C ' C C) CI ) C) C) C ZZr '. Z Z Z OCC6 7- - z -Z z 000 t - o r- - C' r 00 rN 00 N 00 00 "10 N N N cn C) C) C> c CD C) C) C) C: ) C) C), m C- -: CD-)m n C m 060NC ) C -Ci C)c) CD c) CD C) C) C) CD C) C) Cr) C) rA (f C I ) C) LC) C) C) CD' C) C\~ ON C) ON C cd kd' C) kr (D C) C) CfN C) C)CD' C) C) (ND C0)- 5 6. C:, 00 5 ON : - 5 C), C C:, C:) Q) C) D V)~C (NJ Cl') kn Lnf')n n k V) VC) Cl) C) C C) C) LI) VN ON kn On On zC t) C) Co r-- C) ) C) +) + .~. ~ j ~ LI' L') LI) L') LI) I') LI) I' LI) I' Z HZ + Table 8 TGA Tests- Carbonylation Atm 500C) of Reduced Matte Calcine_ (Sample "E" with 4% Fe); Effect of varrying reducing gas strength, oxia n Potential and reduction temperature, and of varrying sulphide activation IeveI Sulphiding level 0 1.0% 1.0% 2.0% 4.0% 6.0% 4.5% 6.0% 6.0% Reduction Reduction atm Temperature Reduction atm 50% H 2 0/50% C _Reduction atm 100% Hz 30% H 2 0/70% H 2

H

2 Sample size 5.5g 5.5g 5.5g 5.5g 5.5g 5.5g 5.5g 5.5g Extraction time. Hours 90 44 0 60.0 444 Ni extraction (%) 67% 74% 79% 86% Fe extraction 425 (%) 54% 52% 38% 35% Extraction time. Hours 14 0 60 0 240 440 42,0 440 44.0 44.0 Ni extraction ~- (%) 31% 45% 42% 65% 79% 61% 71% 61% Fe extraction 500 (%) 29% 38% 31% 36% 29% 30% 23% 18% Extraction time, Hours 440 Ni extraction 0/%) 62% Fe extraction 550 (% 19% Sulphiding at 100*C and atmospheric pressure A other sulphiding at 50 0 C and 15PSI pressure 25 Table 9 TGA Tests: Carbonylation (Atm., 50*C) of Reduced Matte Calcine (Sarm"ple "F" with 2%Fe); Effect of varying reducing atmosphere and reduction temperature, and of varying sulphide activation levels (1%S to 6%S) at 50 0 C Sulphiding lev I Sulfur level 1.0% 2.0% 4.0% 4.5% 6.0% 3.0%wt S 3.0%wt. S 3.0%w S 4.5 wt. % elemental Reduction temperature, Reduction atm Reduction atm Reduction atm Reduction atm Red CReduction atm 100% H2 10%H20-90% H, 20%H20-80% H2 30%HO-70% H, 30%H,0-70% H, 100* H, Sample size 59 Sg Sg 59 5g Extraction time, Hours 44 44 68 - 44 24 Ni extraction M- --- 8% 7 88% 4g% Fe extraction 425 21% 21% 8% 15% 1 Extraction time, Hours - __44 44 44 44 44_____ 44 4 Ni extraction --- 82 4% 74% 1 5% 80% 79% 75% Fe extraction 500 (%) 14% 5% 12% 26% 0.8% ND ND + Reaction was "dead" after 24 hours. ND - Not detectable Table 10 TGA Tests: Carbonylation (Atm., 50*C) of Reduced Matte Calcine (Sample "F" with 2%Fe); Reduction effected with higher oxygen potential gas (30% H 2 0 in hydrogen) at 500*C, Effect of varying sulphide activation levels (2%S to 4.5%S) and temperatures (30 0 C to 150 0 C) Sulfiding Temp. with H@ gas 5(WC 70 100C 120"C 135C 15(10 30"C 3.70' 5 Sufmiding Ptassum ( aspene 15 Reducton Temp. *C Sulfur level 2.0% 30% 3.0% 3.0% 3.0% 3.0% 3.0% 30% 4.5% Extraction time. Hours 44 44 44 44 44 44 44 44 Ni extraction (%) 69% 72% 79% 79% 7D% 51% 32% 71% 75% 500, Fe extraction (%), 13% 6% ND ND ND No 11% N * Reactor was heated up between 30-70 0 C and sulfiding was done during the temperature rise ND - Not detectable 26 Example 8: Tests related to the processing of an intermediate Nickel-Cobalt Hydroxide material produced by acid leaching of a limonitic laterite ore A series of TGA tests was carried out to establish optimum processing conditions for the extraction and recovery of refined nickel from an intermediate nickel-cobalt material, "G" 5 in Table 1. Reduction temperature, degree of sulphiding with H 2 S gas, pressures and times employed for carbonylation were varied while pure hydrogen was employed for reduction and temperature for carbonylation was maintained at 30-85"C. The results are summarized in Table 11 and depicted in Figures 6 and 7. It is demonstrated that nickel hydroxide intermediate with 32 w/w % of nickel and 4.5 w/w % of cobalt yields some 50% or less of its [) nickel to the formation of nickel carbonyl at atmospheric reaction pressure and with no sulphur activation, even after extended carbonylation reaction times. However, increasing the reaction pressure moderately to 700kPa, even with no sulphur activation, results in nickel extraction of some 90% in as little as 8 hours. Pre-sulphiding with H 2 S at the lower temperature of 50'C, provided a high nickel 5 extraction of 78% in 7 hours at a pressure of only I OOkPa, in Test G 11, described in Table 11, and depicted in Figure 7. In other tests, G26 and G30, the nickel extractions at 100 kPa reached as high as 74% in 42 hours. Additional tests were carried out on larger laboratory samples of 20grams, employing 0 a packed bed reactor for the reduction, for the low temperature sulphiding with H 2 S and for the carbonylation, wherein the carbonylation temperature was either 50*C or 30*C and carbonylation pressure was at 100 kPa or under. As seen in test GT-3, a high extraction of nickel was achieved at a carbonylation pressure of 100 kPa and nickel was preferentially carbonylated in comparison with the cobalt, thereby raising the Ni:Co ratio from 7.2:1 in the Z5 feed to over 700:1 in the nickel product plated after decomposition. Carbonylation at 70 kPa in test GT-4 yielded nickel extraction of 59 % in 40 hours, and the nickel to cobalt ratio was increased to 1700:1 in the product. These extraction results are decidedly better than those achieved in the TGA tests, no doubt due to the better gas-solids contact. Although this disclosure has described and illustrated certain preferred embodiments 0 of the invention, it is to be understood that the invention is not restricted to those particular embodiments. Rather, the invention includes all embodiments which are functional or mechanical equivalence of the specific embodiments and features that have been described and illustrated. 27 r- 0 00 00 ti-) i kr 0 00 co 00 0 0 00 .m (JC 00 00(N 0Q C) C>k) C) C) C) C C) C) r C) C) C )C D D C )C C) C) C) C) C) C) C) C) C) "0o C C)

W-

kC ) C v a- aa a a a(D C C) GO -~ -' -~ CO (w I a aj~ U) W) C)C) C CD C) C ) C w:j C) k) CD C D ) C C D C C) CD C) CD C) CD)C) C) CD CD CD CD CD C) W) 00 ON C - c 00 4) .~ ~ N (N (N (N (N + 00 UC) ca , C) C- (Z C:.) kf) kr + r V) ~ ~ 0C)

-

0( 0) ) C /) __ __cj Q~c &.. . CD C) : : C)0 C) C D ) C C ) C D C C)D 0 (n V Q.) Q)U 00 U)) C/) C- ') 4)7 k* 0M4 00 0 o ~ 00 0 0 cJn c~ c c . N U) o to w *~ E- 0 0 NiNN .0 0 0 en

Claims (14)

1. A method of recovering metals, comprising: reducing a mixed metal oxide composition comprising oxides of nickel, cobalt, copper and iron in a hydrogen atmosphere to produce a mixture of the respective metals, the 5 improvement wherein said atmosphere further comprises water vapour at a concentration, temperature and time to effect selective reduction of said oxides of nickel cobalt and copper relative to said iron oxide to produce said metallic mixture having a reduced ratio of metallic iron relative to metallic nickel, cobalt and copper as compared to that in the mixed metal oxide composition; 10 effecting sulphidization of metals within said metallic mixture, for effecting production of a post-sulphidization material; and contacting the post-sulphidization material with carbon monoxide.

2. A method as claimed in claim 1 wherein said mixed metal oxide composition has an iron oxide content of no more than 4% w/w Fe. 15

3. A method as claimed in claim 1 wherein said mixed metal oxide composition has an iron oxide content of no more than 2% w/w Fe.

4. A method as claimed in any one of claims 1 to 3 wherein said mixed metal oxide composition is a nickel smelter product.

5. A method as claimed in any one of claims 1 to 3 wherein said mixed metal oxide 20 composition is a nickel-cobalt leach product.

6. A method as claimed in any one of claims 1 to 5 wherein the reducing is effected at a temperature selected from 350 0 C to 550 0 C.

7. A method as claimed in claim 6 wherein the reducing is effected at a temperature of about 500 0 C. 25

8. A method as claimed in any one of claims 1 to 7 wherein said atmosphere, during the reducing, further comprises an inert gas.

9. A method as claimed in any one of claims 1 to 8 wherein said atmosphere, during the reducing, further comprises a gas selected from carbon monoxide and carbon dioxide.

10. A method as claimed in any one of claims I to 9 wherein said atmosphere, during the 30 reducing, comprises a hydrogen:water ratio selected from 10:1 to 1:1. 31

11. A method as claimed in claim 10 wherein said hydrogen:water ratio, during the reducing, is selected from 3:2 to 2:1.

12. A process as claimed in any one of claims 1 to 11 wherein said hydrogen atmosphere, during the reducing, comprises 10 - 50% v/v water. 5

13. A process as claimed in claim 12, wherein said hydrogen atmosphere, during the reducing, comprises 25 - 35% v/v water.

14. A method as claimed in claim 1, substantially as hereinbefore described. 32