Figure - uploaded by Dr. Abhilash
Content may be subject to copyright.
Source publication
In this review, resources of nickel and status of different processes/technologies in vogue or being developed for extraction of nickel and associated metals from both primary and secondary resources are summarized. Nickel extraction from primary resources such as ores/minerals (sulfides, arsenides, silicates, and oxides) including the unconvention...
Citations
... [24][25][26] Nickel is found in sulphide ores, laterite ores, in secondary resources, and non-land resources like sea nodules. 27,28 Lateritic and sulfides ores are the major important nickel sources. 29 Pentlandite [Ni,Fe)9S 8 ] and nickeliferous pyrrhotite are two important Ni minerals found in sulphide ores. ...
The continuous increasing of the global demand of copper and nickel metals raises the interest in developing alternative technologies to produce them from copper sulfide ore. Also, in line with Egypt's vision 2030 for achieving the sustainable socioeconomic development which aims at developing alternative and eco-friendly technologies for processing the Egyptian ores to produce these strategic products instead of its importing. These metals enhance the advanced electrical and electronic industries. The current work aims at investigating the recovery of copper and nickel from Abu Swayeil copper ore using pug leaching technique by sulfuric acid. The factors affecting the pug leaching process including the sulfuric acid concentration, leaching time and temperature have been investigated. The copper ore sample was characterized chemically using X-ray fluorescence (XRF) and scanning electron microscope (SEM-EDX). A response surface methodology develops a quadratic model that expects the nickel and copper leaching effectiveness as a function of three controlling factors involved in the procedure of leaching was also investigated. The obtained results showed that the maximum dissolution efficiency of Ni and Cu are 99.06 % and 95.30 %, respectively which was obtained at the following conditions: 15 % H 2 SO 4 acid concentration for 6 hr. at 250 ℃. The dissolution kinetics of nickel and copper that were examined according to heterogeneous model, indicated that the dissolution rates were controlled by surface chemical process during the pug leaching. The activation energy of copper and nickel dissolution were 26.79 kJ.mol −1 and 38.078 kJ.mol −1 respectively; and the surface chemical was proposed as the leaching rate-controlling step.
... China alone accounts for close to 52% of world nickel demand. Annual production of electric vehicles (comprising 49%-60% Ni wt%) will reach 31 million in 2025, increasing high pure demand from 33 kt in 2017 to 570 kt in 2025 (Meshram et al., 2019). However, the world reserves of nickel are estimated at 74 million tons of Ni metal content (U.S.-Geological-Survey, 2018). ...
Objective: Niccolite, a rare nickel arsenide mineral, has emerged as a promising source for nickel extraction. However, its processing is limited and often associated with toxicity concerns. This study aims to search for efficient separation of arsenic during the roasting process of niccolite.
Methods: The arsenic-containing phase was optimized through changing the contents of oxygen, additive S, and additive FeS in the system to achieve efficient separation of arsenic during the roasting process of niccolite. Thermodynamic analysis was performed using the equilibrium composition module with HSC Chemistry.
Results: The thermodynamic results showed that in direct roasting, the product contained ferric arsenate which immobilized arsenic in the solid phase, increasing the difficulty in separation. In the presence of sulfur, the arsenic may escape completely in the form of gas (As2O3, As4O4, As4O6). The use of FeS as the reductant significantly reduced the residual arsenic content.
Conclusion: The FeS reduction in roasting process is an optimal strategy for arsenic removal from niccolite. This provides a novel technique for nickel extraction in industry.
... Nickel is the 24th most abundant metal in the earth's crust and it constitutes almost 3% of the earth's composition (Frank Crundwell, 2011). The three oxidation states of Nickel in natural water are (+ 2, + 3, and + 4), although Ni 2+ omposition (Meshram and Abhilash, 2019). ...
Millions of individuals worldwide regularly use cosmetics, personal care items, and tattoos. Tattoo ink and other makeup cosmetics also contain potentially toxic heavy metals. Heavy metals may build in the body after prolonged exposure. Most of them, including Pb, Cd, Hg, As, and Sb, are carcinogenic, allergenic, neurotoxic, teratogenic, and mutagenic contributing to hair loss and other cosmetic issues. Despite of numerous researches around the world and regulations on cosmetic items in developed countries to determine safe levels of heavy metals, most consumers have not knowledge enough about the related risks, especially in developing nations where equivalent regulations are absent. In addition, everyday discarded cosmetics by customers pollute the environment, pose threats to microbes, plants, and animals, and are found in the solid waste and wastewater created by the cosmetic business. For these reasons, research, analytical analysis, publishing, surveying, reviewing and enhancing consumers' understanding of current laws, regulations, legislation , and recommendations of the U.S. Food and Drug Administration (US FDA), World Health Organization (WHO), U.S. Environmental Protection Agency (US EPA), and others are all necessary to raise public awareness about the hazards posed by heavy metals. The current mini-review aims to summarize cosmetics and tattoos' historical background and development, focusing on their hazardous ingredients, health impact, and allowable levels of heavy elements according to regulations.
... [2] The demand for nickel has been steadily increasing in the 21st century, driven by the growing demand for electric vehicle batteries. [3] The global nickel reserve is estimated to be around 100 million tons, with Australia, New Caledonia, and Indonesia having the highest nickel deposits. [4] Nickel laterites and sulfides are the two major categories of nickel ores. ...
... As shown in Figure 5(a), it can be seen from the XRD analysis of sulfated ore from three types of laterite that after sulfation process all phases detected were in forms of hydrate metal sulfates or MeSO 4 AExH 2 O. This verifies the reaction between mineral ore fraction and sulfuric acid produced metal sulfates corresponding to Eqs. [3] through [7] and the hydrate forms of sulfates as a result of moisture addition during sulfation process. The iron sulfates (FeSO 4 and Fe 2 (SO 4 ) 3 ) formed during sulfation as the result of reaction between goethite and sulfuric acid or reaction between iron associated within silicate and sulfuric acid. ...
The demand for nickel has been steadily increasing in the 21st century, primarily driven by the rising demand for electric vehicle batteries. Nickel in laterite is associated within silicate in saprolite ore and hydroxide/oxide in limonite ore. Recently, the sulfation–roasting–leaching process has been developed to address the challenges of extracting nickel from laterite ores. It involves the formation of sulfates through the sulfation process using sulfuric acid. During the roasting process, iron sulfates decompose to produce SO3 gas. The SO3 gas then reacts with oxides, leading to the formation of soluble nickel and cobalt sulfates during the water leaching process. However, most of the previous researches focus on limonite-type ore resulted in limited understanding on saprolite-type ore. The focus of this study is to observe the behavior of nickel and cobalt extraction, from saprolite-type ores through sulfation–roasting–leaching process. It was found in this research that addition of sulfuric acid up to 0.8 ml/g with moisture 40 wt pct followed by roasting process at 700 °C for 30 minutes and leaching process at 80 °C for 30 minutes resulted in the extraction of 70 pct of nickel and 68 pct of cobalt in the derived optimal conditions. It was also found in the evidence that the presence of magnesium oxide in the ore posed a challenge as it thermodynamically favored reacting with the SO3 gas over the nickel and cobalt oxides. Additionally, the presence of SiO2 originating from serpentine minerals affected the recovery of nickel and cobalt due to their adsorption onto amorphous silica during the leaching process. These factors may have contributed to the lower recovery observed in the results of this study.
... The processing of nickel laterites falls into two broad categories pyrometallurgical and hydrometallurgical (Meshram, Abhilash, and Pandey 2019;Wang et al. 2017). In hydrometallurgical processing, the two principal processes are the Caron process and the high-pressure acid leach (HPAL) process, but other acid leaching processes such as atmospheric pressure leaching (AL) and heap leaching (HL) are also practiced or are under investigation. ...
Australia has large reserves of limonite and clay-based laterites that are currently underutilized. This review summarizes the latest nickel laterite upgrading studies reported in the literature which use physical beneficiation – only studies reported after the most recent review in 2015 included – as well as high-temperature methods involving oxidation/reduction roasting (with and without additives), sulphidation, and other high-temperature methods. The focus of this review is on upgrading limonite ores, but studies using other types of laterites are also discussed for comparative purposes. Oxidative roasting has proven to be ineffective but producing a magnetic phase by reduction roasting then magnetically separating it from gangue minerals has produced nickel grades and recoveries of up to 14% and 99% respectively with limonite ores. The choice of reductant has negligible effect although hydrogen reduction is predicted to occur at slightly lower temperatures and recoveries are slightly lower compared with carbon-based reductants. The addition of sulfurous compounds improves agglomeration of ferronickel particles, increases the nickel grade and recovery. The highest recovery of 97.91% (grade 13.62%) was reported when sulfur was used as an additive during the roasting of a limonite ore with coal and limestone at 1400°C for 6 h. The results show reduction roasting followed by magnetic separation is effective for upgrading nickel ores, but challenges with this technology are the potentially high reagent usage and temperatures required. The economic feasibility for processing limonite ores via this route is not clear and should be investigated further.
... 6 In fact, numerous studies have been made on recovery of nickel from primary and secondary resources. 7,8 Namely, secondary resources containing nickel, such as spent LIBs and catalysts, can be good raw materials for the recovery of nickel. Since these secondary resources contain other metals together with nickel, hydrometallurgical operations are generally employed to separate the target metal ions from their leaching solutions. ...
BACKGROUND
Sludge resulting from petroleum refining contains metal oxides such as nickel, copper, aluminum, iron, zinc, calcium, and magnesium. Since the demand for nickel is increasing, a process was proposed to recover pure nickel metal powder from this sludge. In this study, leaching, cementation, precipitation, solvent extraction, and chemical reduction operations were carried out and employed for the recovery of nickel powder from sludge.
RESULTS
Nickel oxide was first completely dissolved using 0.3 mol L⁻¹ H2SO4 solution at a pulp density of 50 g L⁻¹. The leaching solution contained Al(III), Ca(II), Cu(II), Fe(III), Mg(II), Ni(II), and Zn(II). Most of the copper, magnesium, nickel, and zinc were completely dissolved at this step. Copper(II) was removed by cementation with iron powder. After oxidizing Fe(II) to Fe(III) using H2O2, Fe(III) and Al(III) were simultaneously separated by precipitation of their hydroxides at a solution pH of 4. Five stages of cross‐current extraction of Zn(II) with saponified Cyanex 272 led to a raffinate containing only Ni(II), Ca(II), and Mg(II). Nickel metal powders were recovered from this raffinate by chemical reduction with hydrazine.
CONCLUSION
The mass balance of the continuous experiments verified that 99% of the nickel was recovered from the sludge as metal powders with extra high purity. In these separation steps, optimum conditions were obtained and a simple and efficient process was proposed to recover pure nickel metal powders from the sludge. © 2023 Society of Chemical Industry.
... It should be mentioned that while stainless steel production consumes the majority of nickel, the usage of nickel in electric vehicle batteries is growing, resulting in a considerable increase in nickel demand in the near future (Henckens and Worrell 2020). Sulfide ores have historically provided most of the nickel production, with laterite ores contributing only a minor contribution (Meshram et al. 2019). However, in terms of known nickel resources, laterites account for roughly 60% of the total, while sulfides account for 40% due to the complexity of processing nickel laterites compared to sulfides (Jessup and Mudd 2008). ...
... Hasil pengujian ini membuktikan secara ilmiah bahwa komposit spent ore dan residu Fe tidak beracun pada organisme hidup (Razika & Djouani, 2022). Dengan demikian spent ore dan residu Fe ini dapat dimanfaatkan untuk berbagai keperluan yang bersinggungan dengan organisme hidup tidak terkecuali manusia (Meshram et al., 2019). Oleh karena itu, jika spent ore dimanfaatkan untuk media tanam maka dapat mendukung kelangsungan hidup tanaman. ...
In pace with the rising output of electric vehicles, the nickel sector is still developing quickly. In 2022, Indonesia will manufacture 500,882.27 tons of ferro nickel, of which 197,758 tons, or 30.01%, will be able to be sold. Along with the growth of nickel mines comes technological advancements, one of which is the ability to manage wasted ore, a waste product of the nickel refining process. With the help of this study, used ore will be transformed into a useful product that can be used to control the environment. Laboratory scale testing, field scale tests, and toxicity tests (TCLP and LD50) are the techniques used. Testing for toxicity and planting on 14 tonnes of wasted ore, a byproduct of hydrometallurgical heap leaching. Limestone or a combination of biolite, agromax, and ND-201® were used to neutralize the spent ore and Fe residue composites during the process. This seeks to make the leftovers from the leaching process, the resulting runoff water, and the plants that can come from it edible. According to the test results, processed spent ore is a harmless substance that does not fall under the B3 waste category and may be utilized as an excellent planting medium for perennials and food plants. Based on BPOM quality criteria in Law No. 23 of 2017, the results of food laboratory testing revealed that food crops grown through the planting procedure utilizing discarded ore media were suitable for eating.
... The process works at temperatures and pressures in the range of 230 -270 °C [2] and 30 -56 bar [3] respectively. Metals are separated based on their difference in solubilities and other electrochemical properties such as redox potentials and conductance of the metal [4] . The leaching mechanism in the autoclave involves the acid dissolution of the major constituent of the mineral matrix, followed by hydrolysis and precipitation of insoluble oxides and sulphates of iron, aluminium, and silica. ...
... Some electrolytes were observed to give inconsistent values from regression [61] . Using Cp as a reference, due to the strong electrostatic interaction of Mg 2 + and SO 4 2 − in water, the linearization approximation of the Debye-Hückel theory is unsatisfactory [68] . The effects of ion associations on different apparent molal properties can be established at different ionic strengths. ...
... In the case of MnSO 4 °dissociation reaction, The comparison of the equilibrium constant of the species obtained with van't Hoff, "Cp approximation ", Density and unexpanded HKF models in Fig. 3 using data from Liu & Papangelakis [1] and the Thermoddem database show a little difference at a lower temperature which increased with temperature for the van't Hoff, "Cp approximation " and the Density models contrarily to the unexpanded HKF model in Fig. 3 database. The values reported for SO 4 2 − , Fe 3 + , and FeSO 4 + species by Papangelakis & Demopoulos [79] were used for the computation of "Papangelakis 1990 ″ in Fig. 4 [1] for the van't Hoff, "Cp approximation " and Density equilibrium constant models ( Fig. 5 (a, b & c). While the unexpanded Helgeson model shows a negligible difference between the computed results with data from both sources ( Fig. 5 d). ...
Encrustation occurs in many processing fluids where high levels of dissolved solids are present, especially in processes that use heat transfer equipment. The deposition of these scales in the interior surfaces of an autoclave can cause major issues in the operation of industrial processes such as hydrometallurgy. The knowledge of the minerals' chemistry, distribution of the chemical forms of these minerals in the autoclave, and their solubility product can assist to inhibit these solid deposits. To model such systems, it is necessary to know the reactions involved and by extension their equilibrium constants. These electrolytic systems being strongly non-ideal, models of activity coefficients are necessary to deduce the concentration of each species. This review presents and compares various models for the calculation of activity coefficients and the thermodynamic equilibrium constants at temperatures above 25 °C. For model validity and comparison purposes, a case study on the speciation of the aqueous binary systems of H2SO4-Al2(SO4)3 and H2SO4−MgSO4 is presented and compared with experimental data. From the results obtained and in the framework presented above, the Density equilibrium constant model coupled with the Truesdell-Jones activity coefficient model gave the best fit with experimental data at the studied temperatures of 235, 250, 270, and 300 °C.
... The High-Pressure Acid Leaching (HPAL) mechanism consists of the dissolution of the desired metals (Ni, Co, etc.) from the mineral matrix with strong acid, followed by the hydrolysis and precipitation of insoluble oxides and sulphates of iron, aluminium, and silica. In hydrometallurgy which utilises high temperatures and pressures in the range of 230-270 o C (Whittington & Muir, 2000) and 30-56 bar (Gultom & Sianipar, 2020), respectively, metals are separated based on their difference in solubilities and other electrochemical properties (Meshram et al., 2019). ...
Supersaturation occurs in many industrial applications promoting reactive crystallisation between the reactants to form solutes. These solutes accumulate during precipitation, leading to the formation of scales on the inner walls of the reactor and particularly around the stirrer, causing modifications in the hydrodynamics. This encrustation is responsible for process shutdowns in continuous crystallisation processes. Supersaturation control is essential for industrial processes aimed at controlling or inhibiting the formation of these solids. Knowledge of mineral solubility and chemical speciation is required to account for the composition of the complexes in the system in their various solid or aqueous forms. This speciation is obtained by considering the thermodynamic equilibrium constants of the dissociation/complexation reactions involved in the system, the pressure, and the activity coefficients of the chemical species in their molecular or electrolyte form. From these thermodynamic quantities and the state of the system, we can predict the direction of the reaction. This study highlights the risk of the lack of experimental information on equilibrium constants at high temperatures and moderate pressures. Our goal is to evaluate the accuracy of existing models classically used to predict the equilibrium constant in such very hard conditions encountered in hydrometallurgical processes. Furthermore, we demonstrate the influences of equilibrium constants estimation and activity coefficient models on the speciation of H2SO4-Al2(SO4)3-MgSO4 systems, forming hydronium alunite and kieserite in the laterite liquor of hydrometallurgical processes.
