GB2104053A - Production of nickel and cobalt sulphates and chlorides - Google Patents

Production of nickel and cobalt sulphates and chlorides Download PDF

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Publication number
GB2104053A
GB2104053A GB08222300A GB8222300A GB2104053A GB 2104053 A GB2104053 A GB 2104053A GB 08222300 A GB08222300 A GB 08222300A GB 8222300 A GB8222300 A GB 8222300A GB 2104053 A GB2104053 A GB 2104053A
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salt
nickel
cobalt
dissolution
tank
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GB08222300A
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GB2104053B (en
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Eric August Devuyst
Alexander Illis
Victor Alexander Ettel
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Vale Canada Ltd
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Vale Canada Ltd
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    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01GCOMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G51/00Compounds of cobalt
    • C01G51/10Sulfates
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01GCOMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G51/00Compounds of cobalt
    • C01G51/08Halides
    • C01G51/085Chlorides
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01GCOMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G53/00Compounds of nickel
    • C01G53/08Halides
    • C01G53/09Chlorides
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01GCOMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G53/00Compounds of nickel
    • C01G53/10Sulfates

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)

Abstract

Nickel or cobalt sulphate or chloride is prepared by dissolving pieces of the respective metal having a surface area not exceeding 0.5 m<2>/kg in hot sulphuric or hydrochloric acid and cooling the salt solution below 30 DEG C to crystallize the salt.

Description

SPECIFICATION Production of nickel and cobalt salts The present invention relates to the production of nickel and cobalt salts.
The present invention is based on the appreciation that very pure cobalt and nickel salts can be produced directly from metal in a two stage process. Despite its apparent simplicity, we believe that the process of the present invention has not previously been proposed and in particular has not been proposed on an industrial scale.
According to the present invention there is provided a process of producing a chloride or a sulphate salt of nickel or cobalt, which comprises dissolving pieces of metallic nickel or metallic cobalt having a particle size such that their surface area per kilogram is not greater than 0.5 m2, and preferably not greater than 0.2 m2, and more preferably not greater than 0.1 m2, in sulphuric or hydrochloric acid at a temperature in the range of from 50 to 900C to produce a solution of the salt having a concentration in excess of the solubility limit of the salt at ambient temperature; then maintaining the temperature within the range of from 0 to 300C, preferably from 10 to 250C, to crystallize the salt from the solution; and separating the salt from the solution.
The process of the invention is advantageous over the present-day standard process of producing nickel and cobalt salts which involves the dissolution of the relevant metal oxide in acid. Firstly, the process of the present invention requires lower capital cost for the necessary plant than the presently practiced process because it does not require equipment for purification and evaporation operations.
Secondly, the process of the present invention involves fewer process steps than the known process and hence is cheaper to operate. Thirdly, the dissolution of nickel and cobalt in acid is exothermic and, under optimised conditions, temperature can be maintained in the dissolution tank with minimal heat input. Fourthly, the mother liquor remaining after the crystallization step of the process of the present invention may be, and preferably is, re-cycled and hence there is no effluent produced by the process.
Finally, high purity salts can be obtained because high purity metals can be used as feed-stock. Thus, for example, cobalt chloride containing less than 0.05% sulphur can be obtained.
The process of the present invention may be operated as a batch or a continuous process aithough the latter is preferred because it makes more efficient use of available plant. Thus, it is preferred that the dissolution and crystallization stages are done in different vessels.
After the salt has crystallized, it is separated from the depleted mother liquor and preferably washed, with the washing liquor, together with the mother liquor, being added to the liquid used in the dissolution stage. The washing liquor should be chosen so as to reduce to as low a level as possible the amount of crystallized salt that is dissolved in the washing liquor.
The water balance of the system should be carefully maintained. Water leaves the system as water of hydration in the crystallized metal salt and may also evadorate off, e.g. in the dissolution stage.
On the other hand water is added to the system in admixture with the acid fed into the system and may also be added in the washing liquor. When sulphuric acid, which can be obtained as a 98% solution, is used in the dissolution stage, at least part of the water requirement of the process may be added as washing liquor, but preferably no more than about 1 part by weight of cold water to every 10 parts of crystallized sulphate salt. However, hydrochloric acid can be obtained at a maximum concentration of only 36% and consequently contains more water than the amount that leaves the system as water of hydration. The water evaporation loss should, therefore, be sufficiently large to allow for washing liquor and depleted mother liquor to be returned to the dissolution step.In order to prevent the addition of water to the system as washing liquor, it is preferred to wash the crystallized chloride salts with a neutral solution of either nickel or cobalt chloride obtained by neutralising mother liquor with nickel or cobalt carbonate.
The higher the temperature at which the dissolution stage is carried out, the faster it proceeds.
Thus it is preferably carried out at a temperature in the upper half of the 50 to 950C range. Likewise, the lower the temperature in the crystallization stage, the greater is the bite i.e. the amount of salt that crystallizes out, and it is preferred that this stage is carried out towards the lower end of the 10 to 250C range.
The metallic nickel used in the dissolution step may be activated nickel, for example nickel containing about 0.02% sulphur by weight. When cobalt is dissolved in hydrochloric acid, preferably the hydrochloric acid contains a small amount of thiosulphate (S203=) ions to enhance cobalt solubility, as described and claimed in our application No.
The process of the present invention will now be described by way of example only, with reference to the accompanying drawing which shows, in schematic form, apparatus in which the process may be performed. The illustrated apparatus is capable of producing very pure chloride or sulphate salts of either nickel or cobalt in a continuous process.
Start-up Pieces of the desired metal (1 ) having a surface area per kilogram of not more than 0.1 m2 are fed into a dissolution tank together with either hydrochloric or sulphuric acid (2) that has been heated to about 950C in a pre-heated tank. As will be apparent, hydrogen is evolved during the dissolution of the metal and this is permitted to escape from the dissolution tank as shown at (5) via a reflux condensor.
The temperature of the liquor in the dissolution tank is maintained at about 900C by circulating it in a closed loop (4, 3) from the dissolution tank to the pre-heated tank and back again. When the concentration of the dissolved salt is at a desired level in excess of the solubility limit of the salt at ambient temperature, liquor is allowed to overflow from the dissolution tank as shown at (6) to a crystallizer tank and the apparatus is now ready for continuous operation.
Continuous operation Once the flow of liquor to the crystallizer is established, fresh metal is added to the dissolution tank at a rate sufficient to keep the amount of undissolved metal approximately constant and fresh acid is added to the pre-heater in an amount sufficient to keep the concentration of the acid at a steady level.
The temperature in the dissolution tank is kept at about 900C by continuously re-circulating liquor to the pre-heater at a rate of about 7 litres per hour.
Liquor from the dissolution tank is cooled in the crystallizer to about 1 500C by cold water circulating through submerged Teflon coils (Teflon is a Trademark). It is necessary to use coils made from Teflon or some other fluorocarbon material to prevent them from becoming encrusted with crystallized salt. Salt crystals and depleted mother liquor overflow continuously from the crystallizer into a filter which may be a centrifugal or a vacuum device, where the salt crystals (8) are separated from the mother liquor. Periodically the salt is collected, washed and dried. As discussed above, when sulphuric acid has been used to dissolve the metal, the washing liquor (9) is cold water and the amount used is about 10% by weight of the amount of salt to be washed.When using hydrochloric acid, a neutral aqueous solution of the chloride salt (i.e. either nickel or cobalt chloride) should be used. This prevents excessive dissolution of the chloride salt in the washing liquor. The washing liquor and the depleted mother liquor are re-circulated (7) to the pre-heating tank and the process is thus self-contained with no toxic or corrosive effluent streams which have to be treated prior to disposal.
The rate of salt dissolution increases with increasing temperature and accordingly should be as high as practicable e.g. 80 to 950C. The amount of the salt that crystallizes out increases with decreasing temperature in the crystallizer and preferably is as low as practicable e.g. 10 to 200C. The rate of flow of the process streams must be optimised for each plant but that is a relatively simple task for a skilled man. The rate of acid addition is dependent on the metal dissolution rate and, in the case of 98% sulphuric acid as feed acid, water must be added to the dissolution tank to balance the water leaving the system as water of hydration in the metal salt. Part of this water is conveniently added as washing liquor.When using 36% hydrochloric acid (maximum available concentration in commercial hydrochloric acid), an excess amount of water over the water leaving the system as water of hydration in the metal salt is present. This excess water is conveniently removed by evaporation during metal dissolution.
The details of the individual pieces of equipment that make up the apparatus illustrated are as follows: Pre-heating Tank: a cylindrical polypropylene tank 30 cm high and 10 cm in diameter that overflows into the dissolution tank when it contains 1.5 litres of liquid. It is heated by means of 0.6 cm diameter coils made of Teflon and is stirred by a Teflon-bladed impeller rotating at about 200 revolutions per minute.
Dissolution Tank: a cylindrical polypropylene tank 30 cm high and 1 5 cm in diameter that contains about 10 kgs of metal and that overflows into the crystallizer when it contains, in addition to the metal, about 3 litres of liquid. The tank is not equipped with a stirrer. A reflux condenser serves as an exit port for hydrogen generated during metal dissolution. The liquid in the tank is recirculated to the pre-heating tank through a 0.6 cm diameter glass tube whose intake end is located about 1 cm from the bottom of the tank. The re-circulated liquid is pumped using a Masterflex pump and acid-resistant Viton tubing (Masterflex and Viton are Trademarks).
Crystaflizer: A cylindrical polypropylene tank 30 cm high and 10 cm in diameter that is stirred at about 500 to 1,000 revolutions per minute by a six bladed titanium impeller and cooled by water circulating in 0.6 cm diameter Teflon tubing formed into seven ioops each 10 cm in diameter. The crystallizer overflows when the liquid content reaches 1.5 litres.
Filter A vacuum filter having a 25 cm diameter plate. The depleted mother liquor and the washings are re-circulated to the pre-heating tank using a Watson Marlow pump.
Examples of the process of the present invention will now be given. All the Examples were performed in the apparatus illustrated in the accompanying drawings.
EXAMPLE 1 This Example shows the continuous production of cobalt sulphate heptahydrate from electrocobalt rounds having an apparent surface area per kilogram of 0.05 m2. Two tests were performed for 44 and 27 hours respectively. The flow rates and compositions of the process streams at various stages in the tests, together with other operating conditions, are shown in Tables 1 a and 1 b, the numbers in the I hand column of the Tables referring to the streams indicated by the corresponding number in the accompanying drawing.
The composition of the electro-cobalt metal and the salt are given in Table 5.
TABLE 1a Operating Conditions: - 10 kg of electro-cobalt rounds in dissolution tank - 950C in pre-heating tank - 940C at top of dissolution tank - 170C in crystallizer
STREAM ASSAYS DISTRIBUTIONS OF STREAMS (a) (%)/hr based on weight No. Type Flow* of feedstock Co $H2SO4 Co SO4 1 Cobalt Rounds 85X 100(W 0 100 0 2 AqueousH2SO4 0.255 0 565 0 100 3 Pre-heated 8.08 150 100 1,423 1,980 Electrolyte 4 Recirculating 7.00 161 81 1,326 1,716 Electrolyte 5 Hydrogen Gas 32 0 0 0 0 6 Dissolution 1.08 155 90 197 264 - Tank Discharge 7 Mother Liquor 0.825 100 118 97 164 Recycle 8 CoS04.7H20 41 6X 20.4(b) 0 100 100 * measured in litres per hour except when indicated otherwise measured in grams per hour (a) measured in grams per litre except when indicated otherwise (b) measured in weight percentage TABLE ib Operating Conditions: - 7 kg of electro-cobalt rounds in dissolution tank - 950C in pre-heating tank -94 C at top of dissolution tank - 120C in crystallizer
STREAM ASSAYS(a) DISTRIBUTION (%)/hr Based on weight of feedstock No. Type Flowle Co H,SO, Co 1 Cobalt Rounds 31X 100(b) 0 100 2 Aqueous H2SO4 0.09 0 574 0 3 Pre-heated 7.8 145 37 3,656 Electrolyte 4 Recirculating 7.00 150 30 3,387 Electrolyte 5 Hydrogen Gas 12 0 0 0 6 Dissolution 0.79 145 34 370 Tank Discharge 7 Mother Liquor 0.726 115 37 269 Recycle 8 CoSO4.7H2O 148X 21(b) 100 * measured in litres per hour except when indicated otherwise measured in grams per hour (a) measured in grams per litre except when indicated otherwise (b) measured in weight percentage EXAMPLE 2 This Example illustrates the continuous production of cobalt chloride hexahydrate salt from electro-cobalt rounds having a surface area per kilogram of 0.05 m2. Two tests were performed for 20 and 10 hours respectively and the flow rates and compositions of the various process streams, together with other operating conditions, are shown in Table 2a and 2b.
The composition of the electro-cobalt feed and the salt product are given in Table 5 TABLE 2a Operating Conditions: - 10 kg of electrocobalt rounds in dissolution tank - 900C in pre-heating tank - 860C at top of dissolution tank - 200C in crystallizer -5 5 g/l Na2S2O3 solution added at a rate of 20 ml per hour
STREAM ASSAYS DISTRIBUTION OF STREAMS(a) (%)/hr BASED ON WEIGHT OF FEEDSTOCK No. Type Flow* Co HCI Co CI- 1 Cobalt Rounds 110x 1 00(b 0 100 0 2 Aqueous HCI 0.35 0 400 0 100 3 Pre-heated 7.87 230 47.8 1,645 1,928 Electrolyte 4 Recirculating 7.00 245 28.9 1,559 1,714 Electrolyte 5 Hydrogen Gas 42 0 0 0 0 6 Dissolution 0.87 238 39.0 188 214 Tank Discharge 7 Mother Liquor 0.52 186 65.0 88 114 Recycle 8 CoCl2.6H2O 440x 25(b) 0 100 100 * measured in litres per hour except when indicated otherwise measured in grams per hour (a) measured in grams per litre except when indicated otherwise (b) measured in weight percentage.
TABLE 2b Operating Conditions: - 91 0C in pre-heating tank - 9O0C at top of dissolution tank - 1 50C in crystallizer - 5 g/l Na2S2O3 solution added at rate of 15 ml per hour
STREAM ASSAYS DISTRIBUTION OF STREAMS(a) (%)hr BASED ON WEIGHT OF FEEDSTOCK No. Type Flow* Co HCI Co Cl- 1 Cobalt Rounds six 100(b) 0 100 0 2 Aqueous HCI 0.51 0 428 0 100 3 Pre-heated 7.80 257 13.7 3,930 4,042 Electrolyte 4 Recirculating 7.00 266 5.0 1 3,651 3,655 Electrolyte 5 Hydrogen Gas 15.6 0 0 0 0 6 Dissolution 0.74 259 10.0 376 382 Tank Discharge 7 7 Mother Liquor 0.70 200 10.6 275 282 Recycle 8 CoCI2.6H20 210X 23.8'b' 0 100 100 * measured in litres per hour except when indicated otherwise measured in grams per hour (a) measured in grams per litre except when indicated otherwise (b) measured in weight percentage.
EXAMPLE 3 This Example illustrates the continuous production of nickel sulphate hexahydrate salt from electronickel rounds containing 220 ppm sulphur and having an apparent surface area per kilogram of 0.05 m2. Two tests were run under steady state conditions for 40 and 22 hours respectively. The flow rates and compositions of the various process streams together with other operating conditions are shown in Tables 3a and 3b.
The composition of the electro-nickel feed and NiSO4.6 H20 product is given in Table 5.
TABLE 3a Operating Conditions: - 10 kg of electro-nickel rounds (200 ppm S) in dissolution tank.
- 950C in pre-heating tank - 950C at top of dissolution tank - 250C in crystallizer
STREAM ASSAYS DISTRIBUTION OF STREAMS(a) %/hr BASED ON WEIGHT OF FEEDSTOCK No. Type Flow* Ni H2SO4 Ni 1 Nickel Rounds 57X 100(b) 0 100 2 Aqueous H2SO4 0.20 0 500 0 3 Pre-heated 7.97 86 450 1,200 Electrolyte 4 Recirculating 7.00 93 441 1,142 Electrolyte 5 Hydrogen gas 25 0 0 0 6 Dissolution Tank 1.00 90 400 158 Discharge 7 Mother Liquor 0.75 36 515 58 Recycle 8 NiSO4.6H2O 260X 22 0 100 * measured in litres per hour except when indicated otherwise measured in grams per hour (a) measured in grams per litre except when indicated otherwise (b) measured in weight percentage.
TABLE 3b Operating Conditions: - 10 kg of electro-nickel rounds (200 ppm S) in dissolution tank - 950C in pre-heating tank - 950C at top of dissolver - 1 50C in crystallizer
STREAM ASSAYS DISRIBUTION OF STREAMS(a) (%)/hr BASED ON WEIGHT OF FEEDSTOCK No. Type Flow* Ni H2SO4 Ni 1 Nickel Rounds 38x 100(b) 0 100 2 Aqueous H2SO4 0.12 0 565 0 3 Pre-heated 7.42 146 73 2.845 Electrolyte 4 Recirculating 7.00 151 63 2.782 Electrolyte 5 H2 Gas 15 0 0 0 6 Dissolution 0.42 150 70 166 Tank Discharge 7 Mother Liquor 0.30 75 100 59 Recycle 8 NiSO4.6H2O 173x 22(b) 0 100 * measured in litres per hour except when indicated otherwise measured in grams per hour (a) measured in grams per litre except when indicated otherwise (b) measured in weight percentage.
EXAMPLE 4 This Example illustrates the continuous production of nickel chloride hexahydrate salt from carbonyl nickel pellets having an apparent surface area per kiligram of 0.1 m2. These tests were run under steady state conditions for 12 and 24 hours, respectively. The flow rates and compositions of the various process streams together with other operating conditions are shown in Tables 4a and 4b.
The composition of the carbonyl nickel feed and NiCl2.6 H20 product is given in Table 5.
TABLE 4a Operating Conditions: - 10 kg of carbonyl nickel pellets in dissolution tank - 900C in pre-heating tank - 880C at top of dissolver - 170C in crystallizer
STREAM ASSAYS DISTRIBUTIONS OF STREAMS(b) (%)/hr BASED ON WEIGHT OF FEEDSTOCK.
No. Type Flow* Ni HCI Ni CI 1 Nickel Pellets 105* 100(b) 0 100 0 2 Aqueous HCI 0.3 0 438 0 100 3 Pre-heated 8.10 239 49 1,846 2,137 Electrolyte 4 Recirculating 7.00 255 30 1,700 1,851 Electrolyte 5 H2 Gas 40 0 0 0 0 6 Dissolution Tank 1.08 240 50 247 287 Discharge 7 Mother Liquor 0.85 180 63 146 187 Recycle 8 NiCl2.6H2O 420X 25(b) 0 100 100 * measured in litres per hour except when indicated otherwise measured in grams per hour (a) measured in grams per litre except when indicated otherwise (b) measured in weight percentage.
TABLE 4b Operating Conditions: - 10 kg of carbonyl nickel pellets in dissolution tank -90 C in pre-heating tank - 880C at top of dissolver - 11 0C in crystallizer
STREAM ASSAYS DISTRIBUTION OF STREAMS(a) (%)/hr BASED ON WEIGHT OF FEEDSTOCK No. Type Flow* Ni HCI Ni 1 Nickel Pellets 35X 100(b) 0 100 2 Aqueous HCI 0.1 0 438 0 3 Pre-heated 7.5 255 15 5,464 Electrolyte 4 Recirculating 7.00 261 8.7 5,213 Electrolyte 5 H2 Gas 13.5 0 0 0 6 Dissolution 0.482 255 15 351 Tank Discharge 7 Mother Liquor 0.4 220 20 251 Recycle 8 NiCl2.6H2O 140x 25(b) 0 100 * measured in litres per hour except when indicated otherwise measured in grams per hour (a) measured in grams per litre except when indicated otherwise (b) measured in weight percentage.
TABLE 5
ANALYSES METAL FEED (wt%)* or (ppm) OR SALT Co* Ni* Cu Fe Mn Zn Pb Ca Mg Na S Insolubles Electro-Cobalt 99.9 > 0.04 4 15 < 1 3 2 < 5 < 5 < 50 30 Electro-Nickel 0.12 99.9 > < 4 30 - - 5 - - - 200 Carbonyl Nickel < 0.0004 99.9 > < 2 10 - > 2 > 2 - - - 6 CoSo4.7H2O 20.4 0.006 < 0.1 5 < 0.1 < 1 0.6 0.3 0.8 < 0.1 - 15 CoCl2.6H2O 23.8 0.007 0.2 5 0.4 < 1 < 2 0.9 1 10 < 500 5 NiSO4.6H2O 0.026 21.5 < 1 6 - - 1 2 < 1 4 - NiCl2.6H2O 0.0001 25.0 0.5 3 - < 1 < 1 - - < 2 < 100

Claims (4)

1. A process of producing a chloride or a sulphate salt of nickel or cobalt, which comprises dissolving pieces of metallic nickel or metallic cobalt having a particle size such that their surface area per kilogram is not greater than 0.5 m2 in sulphuric or hydrochloric acid at a temperature in the range from 50 to 950C to produce a solution of the salt having a concentration in excess of the solubility limit of the salt at ambient temperature; then maintaining the temperature within the range of from 0 to 300C to crystallize the salt from the solution; and separating salt from the solution.
2. A process according to claim 1 in which the surface area of the pieces of nickel or cobalt used does not exceed 0.1 m2/kg.
3. A continuous process according to claim 1 or claim 2 in which the concentrated salt solution is transferred continuously to a crystallizer maintained at a temperature in the range 10 to 250C.
4. A process according to claim 1, substantially as herein described with reference to any of the Examples.
GB08222300A 1981-08-17 1982-08-02 Production of nickel and cobalt sulphates and chlorides Expired GB2104053B (en)

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4514372A (en) * 1983-03-09 1985-04-30 Inco Limited Process of producing cobalt-containing solutions and salts
CN1047153C (en) * 1996-06-03 1999-12-08 张桂林 Method for preparing cobalt sulfate by chemical reaction
JP2015521984A (en) * 2012-07-10 2015-08-03 ビーエーエスエフ ソシエタス・ヨーロピアBasf Se Method for producing cobalt sulfate aqueous solution
CN113174485A (en) * 2021-04-29 2021-07-27 金川集团镍盐有限公司 Method for deeply removing calcium and manganese in cobalt sulfate solution
EP3967661A1 (en) * 2020-09-09 2022-03-16 Northvolt AB Process for preparing battery grade metal sulphate solutions
WO2023066656A1 (en) 2021-10-22 2023-04-27 Basf Se Processes and systems for producing a nickel sulfate product

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4514372A (en) * 1983-03-09 1985-04-30 Inco Limited Process of producing cobalt-containing solutions and salts
CN1047153C (en) * 1996-06-03 1999-12-08 张桂林 Method for preparing cobalt sulfate by chemical reaction
JP2015521984A (en) * 2012-07-10 2015-08-03 ビーエーエスエフ ソシエタス・ヨーロピアBasf Se Method for producing cobalt sulfate aqueous solution
EP3967661A1 (en) * 2020-09-09 2022-03-16 Northvolt AB Process for preparing battery grade metal sulphate solutions
WO2022053448A1 (en) 2020-09-09 2022-03-17 Northvolt Ab Process for preparing battery grade metal sulphate solutions
CN113174485A (en) * 2021-04-29 2021-07-27 金川集团镍盐有限公司 Method for deeply removing calcium and manganese in cobalt sulfate solution
WO2023066656A1 (en) 2021-10-22 2023-04-27 Basf Se Processes and systems for producing a nickel sulfate product

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Effective date: 19990802