Characterization of Scales Obtained during Continuous

Nickel Laterite Pilot-Plant Leaching

B.I. WHITTINGTON

The processing of nickel by pressure acid leaching nickel laterite ores at 250 8C results in liquors
supersaturated with respect to aluminum, iron, and silica. These can precipitate from the liquor and
onto the autoclave interior (scaling). This reduces the availability of the autoclave. This article presents
a methodology for characterizing scale using X-ray powder diffraction (XRPD), Rietveld analysis of
the XRPD trace, and scanning electron microscopy/microprobe. This methodology is then used to
characterize three scales formed during the continuous (pilot plant) pressure acid leaching of nickel
laterites. Scales formed during the leaching of Western Australian ore, from an acid environment in
hypersaline process water, contain mainly sodium alunite/jarosite as a solid solution together with
minor hematite and amorphous silica. Scales formed during leaching of tropical nickel laterite, in
low salinity process water, consist of an aluminum-rich hydronium alunite with hematite and low
concentrations of amorphous silica. Ore mineralogy, leach liquor composition, acidity, and temperature,
as well as precipitation kinetics, all appear to influence the scale mineralogy. This article discusses
the influence of these factors on the formation of three scales.

I. INTRODUCTION expands upon that by Czerny and Whittington[3] and

THE majority of nickel is currently processed from sul-
fide ores. However, there is a trend toward the processing
of nickel laterite ores, with a particular interest in the pressure
acid leaching process. There are currently four nickel laterite
pressure acid leaching processing plants, one in Cuba (Moa
Bay) and the three plants being commissioned in Western
Australia (Bulong, Cawse, and Murrin Murrin).
Pressure acid leaching involves passing the slurried ore
into segmented autoclaves, operating typically at 250 8C,
and injecting acid into selected autoclave compartments.
The slurry digests at temperature for approximately 1 hour,
and then passes into flash tanks where it cools to approxi-
mately 100 8C. The solid leach residue then separates from
the liquids in a countercurrent decantation thickener well.
The nickel and cobalt present in the liquor are then precipi-
tated either as sulfides (Murrin Murrin, Moa Bay), hydrox-
ides (Cawse), or are extracted directly from the acidic leach
liquor using solvent extraction (Bulong). The nickel sulfide
or nickel hydroxide intermediates are dissolved and further
refined by solvent extraction/electrowinning or, in the case
of the Moa Bay plant, shipped off for further processing.
The formation of supersaturated liquors in the pressure
acid leaching compartments brings with it the possibility of
material precipitating on the autoclave interior (scaling).
Scale deposits in the Moa Bay digestion tanks at a rate of
approximately 300 mm/year. Descaling, which results in a
loss of production, may require 5 days per month.[1,2]
Scaling has been examined in a continuous pilot-plant
system using a Western Australian laterite in hypersaline
water at 250 8C to 265 8C. These results indicate scale can
deposit at approximately 150 mm/year.[3] However, it has
yet to be determined whether scaling will be an issue in the
autoclaves at the Western Australian plants.[17] This article
describes a methodology for characterizing three different
scales depositing within the autoclave during the continuous
nickel laterite acid leaching runs (Table I). This article also
compares the effect of digestion conditions on scale mineral-
ogy by examining scales formed upon leaching a Western
Australian laterite in hypersaline liquor and those formed
upon leaching a tropical laterite in fresh water (Table II).
Typical Western Australian ores consist of approximately
15 pct limonite ore (primarily goethite, FeOOH), 40 to 45
pct smectite clays (nontronite, Fe2 Si4O10(OH)2), and 40 pct
saprolitic ore (serpentine group species, Mg3Si2O5(OH)4),
while the tropical ore consists mainly of alumino goethite.
For comparison, the Moa Bay and Cawse ores are limonite
(goethitic), while the Bulong and Murrin Murrin ores are
serpentine and nontronite rich.[4]
II. EXPERIMENTAL
Scale samples were supplied by Oretest Pty Ltd. following
their pilot-plant campaigns on different ores. Three scales
were selected for detailed investigation. Scales A and B
formed during the acid leaching of Western Australian ore, in
hypersaline process water, at 252 8C or 260 8C, respectively
(Tables I and II). Scale C formed during acid leaching of
tropical ore, in low salinity process water, at 250 8C (Tables
I and II).
A. X-Ray Powder Diffraction
The XRPD traces of the samples were obtained on a
PHILIPS* “XPERT” series diffractometer that used Co Ka
*PHILIPS is a trademark of Philips Electronic Instruments Corp., Mah-
wah, NJ.

radiation and operated at 40 mA/40 kV.

B.I. WHITTINGTON, Research Scientist, is with AJ Parker CRC for Scale samples were ground in a Glenn Creston ball mill
Hydrometallurgy, CSIRO Minerals, Bentley, WA 6102, Australia. for 3 minutes (scale C) or 5 minutes (scales A and B). Scale
Manuscript submitted January 5, 2000. A was ground for a further 12 or 80 minutes in an automated

METALLURGICAL AND MATERIALS TRANSACTIONS B VOLUME 31B, DECEMBER 2000—1175