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Nickel: smelting

Extraction and purification

Nickel is recovered through extractive metallurgy: it is


extracted from its ores by conventional roasting and reduction processes that yield a metal of greater
than 75% purity. In many stainless steel applications, 75% pure nickel can be used without further
purification, depending on the composition of the impurities.

Most sulfide ores have traditionally been processed using pyrometallurgical techniques to
produce a matte for further refining. Recent advances in hydrometallurgical techniques have resulted
in significant nickel purification using these processes. Most sulfide deposits have traditionally been
processed by concentration through a froth flotation process followed by pyrometallurgical
extraction. In hydrometallurgical processes, nickel sulfide ores undergo flotation (differential flotation
if Ni/Fe ratio is too low) and then smelted. After producing the nickel matte, further processing is
done via the Sherritt-Gordon process. First, copper is removed by adding hydrogen sulfide, leaving a
concentrate of only cobalt and nickel. Then, solvent extraction is used to separate the cobalt and
nickel, with the final nickel concentration greater than 99%.

Electrorefining

A second common form of further refining involves the leaching of the metal matte into a
nickel salt solution, followed by the electro-winning of the nickel from solution by plating it onto a
cathode as electrolytic nickel.

Mond process

Purification of nickel oxides to obtain the purest metal is


performed via the Mond process, which increases the nickel concentrate to greater than 99.99%
purity. This process was patented by Ludwig Mond and has been in industrial use since before the
beginning of the 20th century. In the process, nickel is reacted with carbon monoxide at around 40
80 C to form nickel carbonyl in the presence of a sulfur catalyst. Iron gives iron pentacarbonyl, too,
but this reaction is slow. If necessary, the nickel may be separated by distillation. Dicobalt
octacarbonyl is also formed in nickel distillation as a by-product, but it decomposes to tetracobalt
dodecacarbonyl at the reaction temperature to give a non-volatile solid.

Nickel is re-obtained from the nickel carbonyl by one of two processes. It may be passed
through a large chamber at high temperatures in which tens of thousands of nickel spheres, called
pellets, are constantly stirred. It then decomposes, depositing pure nickel onto the nickel spheres.
Alternatively, the nickel carbonyl may be decomposed in a smaller chamber at 230 C to create a
fine nickel powder. The resultant carbon monoxide is re-circulated and reused through the process.
The highly pure nickel produced by this process is known as "carbonyl nickel".

Source: Nickel-Wikipedia

Hydrometallurgy of Nickel

The high temperature (~250C) acid pressure leaching of nickeliferous laterite ore has been
practised commercially since the late 1950's. The acid pressure leach solution is treated using
hydrogen sulphide to produce a high grade sulphide containing at least 50% nickel. This mixed
sulphide is then pressure leached to give a high purity concentrated nickel-cobalt solution, suitable
for solvent extraction to separate the valuable metals. The nickel and cobalt are separately reduced
to metal products.

The flow-sheet below shows the unit operations used in the process.

Source: Acid Leach Process-METMOC

Nickel-Process

The main source of the world's nickel is from copper-nickel sulphide ores with those mined at
Sudbury, Ontario being by far the most extensive. The principle nickel sulphide is pentlandite
(NiFeS2), which is usually associated with chalcopyrite and iron sulphides. International Nickel
(INCO) and Sherritt Gordon use a bulk Cu/Ni float pictured below, followed by selective flotation of
the two elements into separate concentrates. Other Canadian producers leave separation to the
smelters.

Flotation of a Copper/Nickel Ore Containing Pyrrhotite is as follows:

Generalized Flowsheet of the INCO Matte Separation Process is as follows:

Source: http://www.jmeech.mining.ubc.ca/MINE290/proces/nickel.php

Nickel flash smelting

Outotec Nickel Flash Smelting Process is a benchmark nickel-smelting method and a clear
global leader in the worlds primary nickel production from sulfide raw materials. Efficiency and
improved environmental and in-plant hygiene have been the guiding principles in developing the
process.

Process overview

Source: http://www.outotec.com/en/About-us/Our-technologies/Smelting/Nickel-flashsmelting-/

Flash smelting

Flash smelting (Finnish: Liekkisulatus) is a smelting process for sulfur-containing ores


including chalcopyrite. The process was developed by Outokumpu in Finland and first applied at the
Harjavalta plant in 1949 for smelting copper ore. It has also been adapted for nickel and lead
production.

A second flash smelting system was developed by the International Nickel Company ('INCO')
and has a different concentrate feed design compared to the Outokumpu flash furnace. The Inco
flash furnace has end-wall concentrate injection burners and a central waste gas off-take, while the

Outokumpu flash furnace has a water-cooled reaction shaft at one end of the vessel and a waste
gas off-take at the other end. While the INCO flash furnace at Sudbury was the first commercial use
of oxygen flash smelting, fewer smelters use the INCO flash furnace than the Outokumpu flash
furnace. The reactions in the flash smelting furnaces produce copper matte, iron oxides and sulfur
dioxide. The reacted particles fall into a bath at the bottom of the furnace, where the iron oxides
react with fluxes, such as silica and limestone, to form a slag.

Outotec, formerly the technology division on Outokumpu now holds Outokumpu's patents to
the technology and licenses it worldwide. (INCO was acquired by Brazil's Vale in 2006.)

Source: Flash smelting-WIKIPEDIA

Niihama Nickel Refinery

The Niihama Nickel Refinery is the only refinery that produces electrolytic nickel and
electrolytic cobalt in Japan. The Niihama Nickel Refinery started production of electrolytic nickel in
1939. Since that time, it has undergone 2 major production changes, and now produces electrolytic
nickel using the MCLE (Matte Chlorine Leach Electrowinning) method. This MCLE method process
is highly evaluated as an excellent industrial manufacturing technology, making the refinery highly
efficient even from a worldwide standard.

Raw materials

Nickel matte with a 70% nickel grade, procured from mines and smelters that we have a
stake in, and mixed sulfide with a 60% nickel grade produced in Coral Bay, using the HPAL (High
Pressure Acid Leach) process is used as raw material.

Production Process of Electrolytic Nickel

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