PH12014000378A1 - Nickel laterite treatment process for the production of nhp - Google Patents

Nickel laterite treatment process for the production of nhp Download PDF

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PH12014000378A1
PH12014000378A1 PH12014000378A PH12014000378A PH12014000378A1 PH 12014000378 A1 PH12014000378 A1 PH 12014000378A1 PH 12014000378 A PH12014000378 A PH 12014000378A PH 12014000378 A PH12014000378 A PH 12014000378A PH 12014000378 A1 PH12014000378 A1 PH 12014000378A1
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Philippines
Prior art keywords
leaching
process according
stage
nickel
iron
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PH12014000378A
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Tvi Resource Development Phils Inc
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Tvi Resource Development Phils Inc
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Abstract

It is a laterite treatment process to extract nickel and other valuable constituents from both limonite and saprolite ores to produce a saleable hydroxide product while the corresponding waste effluents are treated to suit environmental disposal standards. The leaching section takes advantage of the iron and magnesium content of the ore to induce in process hydrolysis that regenerates acid, thereby minimizing overall acid requirement. Leaching with sulfuric acid is performed in two stages, which is composed of an atmospheric tank leaching stage and a medium-pressure autoclave leaching stage. The high iron, low magnesium size fraction of the ore is leached in the atmospheric tank leaching stage, while the high magnesium, low iron size fraction of the ore is leached in the autoclave leaching stage. The pregnant leach solution undergoes a solution purification stage, which can be either be in the form of ion exchange, solvent extraction, or selective precipitation. The purified pregnant leach solution is the added with a precipitating agent to increase its pH thereby precipitating nickel hydroxide product. Meanwhile waste effluents such as solid leach residue and barren solutions are treated by addition of limestone and lime slurries to meet environmental standards for waste disposal.

Description

II. DESCRIPTION = © A FIELDOFTHEINVENTION -
The present invention relates to the mining and mineral processing field that involves a method for treating nickel laterite ores to extract and recover nickel, cobalt, iron, magnesium, manganese, aluminum, - chromium, and other valuable constituents inherent in lateritic ores to produce a saleable nickel hydroxide product, where corresponding oo effluents are appropriately treated to suit environmental disposal - 40 standards. © [2
B. BACKGROUND OF THE INVENTION 45 Various processes for treating lateritic ores exist and are used depending on the size of the mineral reserve and the project's economic objectives.
One of the most common practice in the industry is employing leaching with sulfuric acid to extract out the nickel and other associated components from the laterites. Two of the known leaching technologies 50 that use sulfuric acid are atmospheric (pressure) tank leaching and autoclave high pressure acid leaching (HPAL). Atmospheric tank leaching is commonly used to treat saprolite ores, while HPAL is usually applied to treat limonite ores. Typical nickel laterite process flowsheets incorporate these two technologies to separately treat limonite and 55 saprolite ores. Moreover, a third leaching stage is usually instated to neutralize the residual acid after leaching by utilizing high magnesium saprolite ores. i
Itis a common practice in the nickel laterite leaching industry to subject 60 the leach slurry to a CCD circuit for solid liquid separation. Depending on the company’s objectives, process variations usually start from the point where the pregnant leach solution (PLS) gets separated from the solid leach residue. The PLS can either undergo extensive purification/ concentration stages or go directly to product precipitation 65 stage.
Treatment of solids and solution wastes are typical practice in the industry to meet environmental standards: :
© C. SUMMARYOFTHEINVENTION
The present invention is a process for extraction of nickel from laterite & ores and recovery of valuable metals contained therein through precipitation. It incorporates unit operations where nickel and other » 75 metals are leached from the ore, and subsequently purified and on precipitated to produce a saleable nickel product. Process wastes are - treated to render them suitable for environmental disposal. 6
Leaching is conducted in two stages leaching that treats both limonite and saprolite © 80 ore using sulfuric acid as lixiviant. The first stage is an atmospheric leach where =O temperature is about 100 °C for a period of around 5 h, while the second stage is a —- low pressure autoclave leach where the temperature is about 150 °C for a period of 2 h. 8s The present invention takes advantage of the inherent iron and magnesium content of the ores to induce in-process hydrolysis that regenerates acid, thereby minimizing overall acid requirement. After leaching, the slurry proceeds to a counter-current decantation circuit (CCD) for washing and solid-liquid separation. The resulting pregnant 90 leach solution (PLS) is then subjected to a solution purification and concentration stage through any of the ion exchange, solvent extraction, or selective precipitation. The purified PLS is then added with a precipitating agent such as NaOH, MgO, etc. to precipitate nickel and cobalt as a saleable nickel hydroxide product (NHP). The barren 95 solution from the solution purification stage is added with limestone to precipitate the iron, and lime to subsequently precipitate out the heavy metals, making the wastewater suitable for disposal. Meanwhile, the solid leach residue from the CCD underflow is neutralized with limestone and lime before disposal. 100 __ D. BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1Figure—1 is a simplified schematic flowsheet diagram of the 10s invention. By referring to this, the succeeding detailed description can be easily understood. : ]
110 or
E. DETAILED DESCRIPTION OF THE DRAWINGS .
Saprolite and limonite ores are blended (1) to achieve the desired iron wr and magnesium ratio and crushed (2). The crushed ore is scrubbed (4) ” 115 to remove fines from the coarse materials. A screen at the end of the Sk scrubbing stage separates predominantly high silica oversize, which is = discarded. The undersize discharges to a vibrating screen for closer sizing. The vibrating screen oversize undergoes secondary crushing © before it gets fed to a ball mill that is in closed circuit with a classifier (6). hy 120 The coarse classifier product is recycled back to the ball mill before it - joins the fine classifier product; together they constitute the secondary leach feed ore. On the other hand, the vibrating screen undersize is thickened (5) before feeding to the primary leaching stage. 125 Primary Leaching (8) is accomplished through atmospheric tank leaching, where a more aggressive leaching environment prevails to maximize Ni extraction at a reasonably low acid consumption.
Therefore, it is in this stage of the leaching section where the concentrated sulfuric acid (7) is introduced and the ore with the highest 130 possible Ni and Fe grades and low acid consumers are fed.
The leaching temperature here is maintained by steam injection, which aids the autogenous heat generated by the exothermic reaction from the mixing of water in the primary leach feed slurry and the concentrated 135 acid. The dissolution of the metals occurs based on the following reactions:
NiO + H2SOs -> NiSO4 + HO , 2FeOOH + 3H2S04 -> Fex(SO4); + 4H,0 140 MeO + H2S504 -> MeSO4 + H20 (Me = other soluble metals in the ore such as Mg, Mn, Al, Cr, etc.)
After primary leaching, the leach slurry combines with the fresh high-
Mg Secondary feed ore as feed to the autoclaves of the Secondary 145 Leaching Stage (9). This stage is designed to auto-generate acid, thus requiring no further acid addition.
The free acid of the primary leach slurry is maintained at a level to start ~~ = secondary leaching. As the primary leach slurry comes into contact with - 150 the fresh secondary feed ore, the free acid leaches out the dominant - alkaline components of the ore such as Mg and other hydroxides. The ho dissolution of Mg, with its alkaline nature, raises the pH of the solution. =
The temperature and pressure in the secondary leach is maintained to Lr promote the precipitation of iron in its ferric (Fe3*) form. This results to - 155 a purified pregnant leach solution (PLS) with essentially much less Fe. o
As can be seen in the following chemical reactions, acid is generated as a © byproduct of this precipitation:
Fez(SO4)s + 4H0 -> 2FeO(OH) + 3H2S04 PE 160 ~~ 3H2504 + (Mg,Ni)3Si207°2H.0 ->3MgSOs (or NiSOq4) + 25i0: + HO -
The generated acid allows the leaching reaction to proceed further thereby reducing the overall acid requirement. An added benefit is the additional leaching of the Ni in the secondary feed ore without incurring 165 additional acid cost.
From the leaching section, the leach slurry goes to a counter-current decantation circuit (CCD) for washing and solid-liquid separation (10).
It is in this stage where the pregnant leach solution gets separated from 170 the solid leach residue. The PLS overflows from the front end of the
CCD, while the thickened pulp of the solid leach residue gets washed as it traverses each thickener and exits as underflow of the back end of the
CCD (i.e. counter-current to the wash water). 175 To make the solid leach residue environmentally suitable for disposal, it is necessary to treat it through a neutralization stage (11). The neutralization stage is composed of a series of heated reactors, where slurries of limestone and lime are added to increase the pH of the slurry t03.0 - 4.5 and 8 - 9, respectively. 180
Coming from the CCD, the PLS proceeds to the solution purification stage (16), which is typically composed of any of the following, ion exchange, solvent extraction, or selective precipitation. This stage purifies the solution of impurities, thereby increasing its nickel 185 concentration. The purified nickel solution is then neutralized by addition of limestone slurry (18) up to pH to 3.0 - 4.5. This step (17) simultaneously precipitates out residual iron in the solution ensuring a cleaner PLS prior to nickel product precipitation. An oxidizing agent @ such as air or H,O; is used to promote oxidation of Fe?* to Fe3*. A " 190 thickener at the end of the circuit separates the neutralized solution from - the Fe precipitates. The essentially Fe-free PLS goes to the subsequent =
Ni Precipitation circuit. =
In the Ni Precipitation circuit (20), solution or slurry of precipitating - 195 agent (19) such as NaOH, MgO, etc. is used to raise the pH of the PLS to a 6.5 - 8.5 thereby precipitating nickel as NHP. After precipitation, the @
NHP pulp goes to a subsequent dewatering (thickening) and filtration “ stages (21) where the final solid NHP (22) is produced. Meanwhile, the = liquid phase of the pulp, together with the barren solution of the 7 200 solution purification stage, proceeds to the wastewater treatment stage. , i
Coming from the NHP precipitation circuit and the solution purification stage, the Ni free solution goes to the Heavy Metals Removal circuit (24), where milk of lime (23) is added to raise the pH up to 9 and precipitate 205 out the heavy metals. The resulting sludge is then thickened (25). The thickener overflow, containing dissolved salts, proceeds to the cooling ponds (26) for eventual sea disposal. Meanwhile, the thickened sludge (thickener underflow) is pumped to the residue filtration stage (14), where it gets filtered together with the leach residue (15). 210

Claims (19)

  1. III. CLAIMS - 215 The claims are as follows: & . Ll (HA complete process for treating nickel laterite ores using a 2-stage leaching circuit consisting of - atmospheric tank leaching and medium - 220 temperature, medium-pressure autoclave leaching to © een meson extract and recover nickel, cobalt and other valuable - constituents inherent in laterite ores. It includes the @ production of a saleable nickel product and the - treatment of waste streams. a 225
  2. 2. A process according to Claim 0% that treats both . . . ve sol limonite and saprolite ore. _
  3. 3. A process according to Claim 1 that takes advantage 230 of the iron and magnesium content of the ores to induce in-process hydrolysis that regenerates acid in the leaching stages, thereby reasonably minimizing overall acid requirement. ~~ ¢¢'t 235
  4. 4. A process according to Claim 3 that exploits the inherent size fractions of the ores to classify the feed ores into high iron primary leaching feed and high magnesium secondary leaching feed. 240
  5. 5. A process according to Claim 4 that subjects the feed ore to size reduction, sizing, scrubbing, and thickening as preparation for feeding to the leaching circuit. 245
  6. 6. A process according to Claim 4 that can treat nickel laterite ores with as high as 25% iron and 20% magnesium. 21k
  7. 7. A process according to Claim 0% that utilizes 250 atmospheric tank leaching in the primary leaching stage to achieve close to 100% nickel and cobalt = extraction within 3-8 hours of residence time at = temperatures near and below the boiling =” temperature. - 255
  8. 8. A process according to Claim 7 that uses H concentrated sulfuric acid to leach out the nickel and - cobalt from the ores. w 260 |
  9. 9. A process according to Claim 0% that utilizes - medium pressure (bouts bar) autoclave leaching in = the secondary leaching stage at temperatures . ranging from 125°C to 180°C within 2-3 hours of o residence time to induce acid regeneration brought 265 about by the hydrolysis of the dissolved iron due to the increase in pH increase.
  10. 10. A process according to Claim 9 that considers the additional leaching of nickel in the secondary feed 270 ore without incurring additional acid cost as added benefit.
  11. 11. A process according to Claim 9 that produces a pregnant leach solution that has a nickel 275 concentration that is always greater than its iron concentration. hull
  12. 12. A process according to Claim 7 that recognizes the inherent self-heating characteristics of the 280 atmospheric leaching stage due to the exothermic reaction of acid with water, but proposes the use of external heating source such as steam injection to optimize and maintain the operating temperature at this stage of the leaching process. 285
  13. 13. A process according to Claim 0% that proposes that after leaching the leach slurry is sent to a CCD circuit for washing and solid-liquid separation prior downstream treatment of the PLS. 290
  14. 14. A process according to Claim 0% that proposes = the inclusion of the treatment of the solid leach - residue coming from the CCD underflow by = addition of limestone and lime to render it suitable i 295 for environmental disposal. =
  15. 15. A process according to Claim 0% that proposes - the inclusion of the treatment of the barren solution ° coming from the solution purification stage and the a 300 nickel hydroxide product precipitation stage by the - addition of lime to precipitate out heavy metals = making the treated solution suitable for environmental disposal. 5 305 |
  16. 16. A process according to Claim 0% that purifies the pregnant leach solution by a solution purification and concentration stage, which is typically ion exchange, solution purification, or selective precipitation. 310
  17. 17. A process according to Claim 16 that includes a succeeding solution neutralization stage by the addition of limestone up to pH 3.0-45 at temperatures above 40°C for 3-6h, thereby 315 simultaneously precipitating out residual iron.
  18. 18. A process according to Claim 0+ and Claim 17 that proposes that the resulting thickened iron precipitates from the neutralization stage be recycled 320 as seed to the medium pressure autoclave leaching.
  19. 19. A process according to Claim 0% and Claim 18 that proposes the precipitation, at pH 6.0-8.5, of a nickel hydroxide product by the addition of 325 precipitating agent such as NaOH at temperatures above 40°C for 3-6h.
PH12014000378A 2014-12-10 2014-12-10 Nickel laterite treatment process for the production of nhp PH12014000378A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PH12014000378A PH12014000378A1 (en) 2014-12-10 2014-12-10 Nickel laterite treatment process for the production of nhp

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PH12014000378A PH12014000378A1 (en) 2014-12-10 2014-12-10 Nickel laterite treatment process for the production of nhp

Publications (1)

Publication Number Publication Date
PH12014000378A1 true PH12014000378A1 (en) 2016-07-18

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