Primary nickel production

• Nickel occurs in nature mainly as a sulphide

pentlandite (Ni,Fe)9S8.
• usually associated with Cu and Fe sulphides
(which makes it a good candidate for smelting
and converting).
• also contains some pgms in small quantities.
• can also be found in hydrous nickel silicate
(laterites) which are mainly processed by
hydrometallurgy.
• Pentlandite ore with a typical Ni content of 1 –
3 % is processed to provide a Ni-S concentrate
containing some copper and Fe as sulphides
and smaller amounts of Co, Ag, Pt as
sulphides, some arsenides and a siliceous
gangue.
• Owing to the similar thermodynamic
characteristic of Ni and cu sulphides, the
major problem is their separation.
• Several pyrometallurgical and hydrometallurgical
extraction techniques used
• Extraction of Ni from the ore follows the same
route as copper and indeed in a number of cases,
similar processes and equipment are used.
• The major differences in equipment are the use of a
higher temperature refractories and the increased
cooling required to accommodate the higher
operating temperatures in nickel production
• The specific processes taken depend on whether
the ore is a sulphide or a laterite
• In the case of sulphides, the reaction of oxygen
with Fe and S in the ore supplies a portion of the
heat required for smelting
• One of the major common equipment in the Ni
and Cu process flow chart is the Peirce-Smith
converter and it accounts for over 90 % of
world production of Cu and Ni.
• The most common route and the one
discussed in this module was developed by the
International Nickel Company (INCO).
• The initial process steps of partial roasting,
smelting and converting are similar to those
used for extraction of Cu from sulphide ores,
eventually providing Ni and Cu sulphides in a
form that can lead to efficient separation of
the two.
• A certain amount of Fe-S is retained in the
calcine after partial roasting to aid autogenous
converting of the NiS-CuS matte
• It is not possible to convert NiS to Ni as was the
case with CuS converting to Cu due to the mutual
reduction reaction between NiS and NiO having a
positive standard free energy change at 1200oC
4NiO + Ni3S2 = 7Ni + 2SO2 ΔGo1200 = +20kJ
• However, smaller amounts of Ni-S and Cu-S are
converted to provide a Ni-Cu alloy containing the
majority of the precious metals present in the
concentrate
• Thus, the main products of the matte converting
operation are Ni and Cu sulphides, which form a
matte and a small amount of Ni-Cu alloy (monel
metal 67:33 Ni:Cu), which contains the PGMs
• The FeS present in the matte is converted to Fe-
oxide providing heat for the process as in the Cu
converting operations
• An acid silica slag is used for the same reasons as in
the Cu making process
• The three products Ni3S2, Cu2S, Ni-Cu alloy are
subsequently cooled slowly through the range 925 –
370 oC, which allows first Cu2S, then Ni-Cu alloy and
finally the Ni3S2 to solidify in large grains.
• These are separated by first crushing and grinding
the matte followed by magnetic separation of the
Ni-Cu alloy and froth flotation separation of the
remaining Ni3S2 and Cu2S
• The Cu2S is sold to a Cu extractor and the Ni3S2 is
treated in various ways to extract Ni.
• The Ni3S2may be cast into anodes and directly
electro-refined into Ni using a diaphragm to
separate the anolyte (electrolyte around the
anode) and the catholyte (the electrolyte around
the cathode)
• If this were not done, impurities (Cu, Co, Fe),
being close to Ni in the electro-chemical series,
would result in contamination of the cathode Ni
• S collects as part of the anode slimes together
with any PGMs that may be present
• Alternatively, the Ni3S2 matte is sintered to
produce NiO which is subsequently reduced
with C or H2 to provide an impure Ni
Ni3S2 + 7O2 = 3NiO + 2SO2 (T= 750oC)
NiO + (C/H2) = Ni + (CO/H2O) (T = 400oC)

• The crude Ni is refined by the carbonyl/ Mond

process