This document provides an overview of nickel ore processing. It discusses the two main types of nickel ores - laterite ores and sulfide ores. For laterite ores, it describes the various processing options including smelting, the Caron process, high pressure acid leaching, atmospheric leaching, and heap leaching. It also provides details on specific nickel laterite deposits and processing plants. For sulfide ores, it briefly mentions that they are mined underground. The document aims to inform the reader about nickel ore characteristics, processing techniques, and the global nickel production industry.

1. Nickel Ore Processing
Prepared By- Mukesh Ranjan Behera 1

2. CONTENTS-
 What is Nickel
 Nickel Physical and Chemical Properties
 Nickel History and Indian Nickel Market
 Formation of Nickel and its Types
 Processing Options relative to deposit type
 Laterite Ore Processing
 Sulfide Ore Processing
 Sukinda COB Analysis
 World Nickel Reserve and Production
 Nickel Uses
2

3. WHAT IS NICKEL-
 Nickel is a strong, lustrous, silvery-white metal.
 Nickel is a chemical element with symbol Ni and Atomic number
28, atomic mass 58 amu (one nickel atom contains 28 protons, 28
electrons, and 30–36 neutrons depending on the isotope).
 Isotopes: Five stable isotopes: Nickel-58, nickel-60, nickel-62,
nickel-61, nickel-64.
3

4. Nickel
Crystal of Nickel Face-centered cubic(FCC) structure. In fact,
about 65 per cent of nickel is used to manufacture stainless steels,
and 20 per cent in other steel and non-ferrous (including "super")
alloys, often for highly specialized industrial, aerospace and military
application.
The most common ores of Nickel include Pentaldite, Pyrrhotite,
Garnierite.
4

5. NICKEL PHYSICAL PROPERTIES
 Color-Silvery White Metal
 Phase-Solid
 Melting Point-1455 degree centigrade
 Boiling Point-2730 degree centigrade
 Density- 7.81 g/cm3
 Conductivity- Fairly good conductor of heat and electricity
 Malleability- It’s capable of being shaped or bent
 Luster- Exhibits a shine or glow
 Hardness- Harder than iron
 Ferromagnetic- Nickel is easily magnetized
 Ductility- It can be beaten into extremely thin sheets.
 It is more resistant corrosion and oxidation. 5

6. 6
CHEMICAL PROPERTIES-
 Nickel is relatively un reactive, but react with strong acids.
 It does not react with alkalis.
Nickel History-
The elements name come from German mythology, Nickel. In
1824 People thought that Nickel as a by product of cobalt.
The introduction of nickel in steel production 1889 was
increased because the demand of nickel increased.
The main deposits in world are New Caledonia in Pacific,Sudbury
Region in Canada, and Norilsk in Russia.
In 1922 -1981 Canada is the largest Nickel Producer in World.
In that time Canada use 99.9% of nickel, in coin producing.
Nickel Occurs nature Principally as Oxides, Sulphides, and
Silicates.
Ores of Nickel are mined in Over 23 Countries and are smelted
or refined in 25 Contries.

7. Indian nickel market
India does not have any history related to the metal nickel.
In India nickel is vary law grade deposit and there is no processing
plant. But as one of the fastest developing nations of the world, Indian
demand for stainless steel and consequently nickel has been rising at a
high rate.
A rising demand and no production makes the country a total
importer of nickel. The country imports around 50000 MT of nickel
annually.
This demand is expected to rise in future with the increase in the
demand of stainless steel. The government has implied import duties
in the import of the metal @ 15%.
Primary nickel is produced and used in the form of Ferro-nickel,
nickel oxides and other chemicals, and as more or less pure nickel
metal. Nickel is also readily recycled from many of its applications,
and large tonnages of secondary or "scrap" nickel are used to
supplement newly mined metal
7

8. FORMATION OF NICKEL ORE-
 Pure nickel shows a significant chemical activity that can
be observed when nickel is powdered to maximize the
exposed surface area on which reactions can occur.
 Even then, nickel is reactive enough with oxygen
that native nickel is rarely found on Earth's surface, being
mostly confined to the interiors of larger nickel–iron.
 On Earth, such native nickel is found in combination
with iron, Earth's inner core.
8

9. Primary nickel is produced from two very different Ores
1. Laterites
2. Sulphides
Laterites ores are normally found in tropical climates where
weathering, with time, extracts and deposits the ore in layers
at varying depths below the surface.
 Laterites ores are excavated using large earth-moving
equipment and are screened to remove boulders.
 Sulphides ores, found in conjunction with copper-bearing
ores, are mined from underground..
Laterite Ore SulphidesOre 9
Characterestics of ore

10. CLASSIFICATION OF NICKEL LATERITES ORE-
A: Hydrous Mg-Ni silicate deposits (~35% of total resource)
serpentines, Nepouite, Garnierite in saprolite
High grade: global mean 1.53% Ni
B: Semecite silicate deposits (~15% of total resource)
Clays content with saprolite and pedolith
Low grade: global mean 1.21% Ni
C: Oxide deposits (~50% of total resource)
Fe and minor Mn oxides, in form of saprolite and pedolith
Low grade: global mean 1.06% Ni
10

11. Laterites include limonites, saprolites and their mixtures
(laterites contain max. 3-4% Ni). Limonite reserves are greater
than saprolites.About 35-40% of world primary nickel production
comes from laterites( but difficult processing, upgrading, high
capital and operating cost compared to Sulphides).
11

12. East Pinares, Cuba, Oxide Goro New Caldonia,Oxide CAWSE Western Australia ,Oxide
PLATEUA,New Caledonia,Silicate
Murrin Murrin Australia
Hydrous Silicate
Bulong Western Australia Semisite Silicate
CIRCE New Caldonia Hydrous Silicate
12

13. 13

14. Lateritic Ore Processing
 Nickel laterite is a complex ore containing several kinds of
metal elements. Nickel present as a minor constituents of other
minerals, therefore, it is not easy to concentration.
 Lateritic ores have a high percentage of free and combined
moisture, which must be removed.
 Drying removes free moisture; chemically bound water is
removed by a reduction furnace, which also reduces the nickel
oxide.
Ni atoms
14

15. PROCESS ORE PRODUCT COMMENT
Smelting
1859, New Caledonia
Hydrous silicate Ferro-nickel
matte
Energy intensive;
(smelting ~1600ºC)
Caron process
Reduction &
ammoniacal leach
1944, Cuba
Oxide; hydrous
silicate
Ni oxide; Ni briquettes Energy intensive
(reduction ~700ºC)
low Co recovery
High pressure acid
leach (HPAL)
1959, Moa Bay, Cuba
Oxide; smectite Ni briquettes;
electronickel; oxide,
sulphide, carbonate
Less energy intensive.
Plant & process
problems
Atmospheric
Leaching
Hydrous silicate Ni-Co hydroxide Atmospheric leach
after HPAL
Acid heap leach
H2SO4
Atmospheric leach
H2SO4
HCl/MgCl2
Oxide; smectite
Oxide; smectite
hydrous silicate
Ni-Co hydroxide Lower capital cost;
Lower recoveries
PROCESSING OPTIONS FOR NICKEL LATERITES-
15

16. PROCESSING OPTIONS RELATIVE TO DEPOSIT
TYPE
Oxide
(or smectite)
Transition
Hydrous silicate
16

17. Hydrous silicate ore
(“garnierite”; serpentine)
Too costly for smectite
e.g., tumbling of boulder ore
1400 - >1600ºC; high energy cost
SiO2/MgO <2 or >2.5
= ferronickel
SiO2/MgO 1.8-2.2
= matte
~77% of total production in 2000
33% or less of new capacity
NICKEL LATERITE PROCESSING
Smelting
F
E
E
D
P
R
O
C
E
E
S
S
Drying
Upgrading
Reduction roast
Smelting
Converting
P
R
O
D
U
C
T
Fe-Ni or Ni matte
90% recovery
Ni: >2.0%
Co: 0.04%
Fe: 20%
MgO: 25%
17

18. High grade oxide ore, some hydrous
silicate; tolerates more Mg than
HPAL. Too costly for smectite.
~700ºC; high energy cost
Complex pyrometallurgical -
hydrometallurgical process; high
energy cost with lower recoveries
than smelting and PAL.
No new plants anticipated
NICKEL LATERITE PROCESSING
Caron process
F
E
E
D
P
R
O
C
E
E
S
S
Reduction roast
Grinding, drying
Leach ammonia cal CO3
Cobalt separation
Ni carbonate precipitation
P
R
O
D
U
C
T
Ni:
94% recovery
Ni: 1.8%
Co: 0.1%
Fe: 25-40%
MgO: <12.0%
Co:
90% recovery
Calcining
18

19. Oxide or smectite ore,
low Mg and Al to reduce acid
consumption
Upgrade oxide by screening to
remove barren silica
High capital costs, with new plants
having numerous teething problems
in plant and process.
Product options include
sulphides: Murrin2, Halmahera
hydroxide: Ravensthorpe, Vermelho
carbonate: Cawse
NICKEL LATERITE
PROCESSING
High pressure acid leaching
F
E
E
D
P
R
O
C
E
E
S
S
Leach H2SO4
Ore preparation
Acid plant
S
Energy
Wash/neutralize
SX-EW or precipitate
P
R
O
D
U
C
T
Ni:
94% recovery
Ni: 1.3%
Co: 0.13%
MgO: <5.0%
Co:
90% recovery
240-270ºC; lower energy cost
Caron process
19

20. NICKEL LATERITE PROCESSING
Atmospheric leaching
F
E
E
D
Oxide ore (but, potentially, any ore
type, including low grade hydrous
silicate)
P
R
O
C
E
E
S
S
Heat and leach
H2SO4
Ore preparation
Acid plant or
excess from
HPAL
S
Energy
Wash/neutralize
SX-EW or precipitate
P
R
O
D
U
C
T
Ni (Co) hydroxide
~80-90% recovery
Ravensthorpe, Gag Island:
oxide, serpentine saprolite (hydrous
silicate)
Sechol: oxide, saprolite
Enhanced high pressure acid
leaching (EPAL); 80-105ºC
Sechol/Jaguar tested HCl/MgCl2
leach at 80-105ºC. Process could
also yield MgO and magnetite
concentrate as products. Trial
discontinued
20

21. NICKEL LATERITE PROCESSING
Heap leaching
F
E
E
D
Potentially, any ore type,
including low grade hydrous
silicate and rejects
P
R
O
C
E
E
S
S
Heap, leach for 12-
18 months
Ore preparation
Acid plant or
excess from
HPAL
S
Energy
Wash/neutralize
P
R
O
D
U
C
T
Ni (Co) hydroxide
~80% recovery
SX-EW or precipitate
Caldag, Nornico - oxide;
Murrin Murrin - smectite
Crush; upgrade by screening to
remove barren silica
Neutralize using low grade
saprolite ore
Suitable for smaller deposits;
low capex and opex
21

22. PROCESSING OPTIONS FOR NICKEL LATERITES
HPAL Atmospheric
leach
Heap leach
Capital
expenditure
$17-22 $13-16 $8-12
Operating
expenditure
$2.50 $2.50 $2.50
$US/lb Ni
Traditional processing (smelting, Caron) is generally very energy
intensive.
 HPAL plants use less energy but require high capital expenditure
and are yet to be fully optimized best suited to large deposits.
 Acid leaching at lower temperatures and ambient pressures offer
lower capital expenditure (but lower recovery).
 Better mineralogical characterization is needed to optimize grade
control, beneficiation and processing.
22

23. FERRO NICKEL ORE-
 A recent development in the extraction of nickel laterite ores
is a particular grade of tropical deposits, typified by
examples at Acoje in the Philippines.
 This ore is so rich in limonite (generally grading 47% to
59% iron, 0.8 to 1.5% nickel and trace cobalt) that it is
essentially similar to low-grade iron ore.
Fe –Ni Ores Processing-
1. Pyro-metallurgy(Rk-EF-75%)
2. Hydro-metallurgy(HPAL-15%)
3. Combined(Caron Process, Rather Obsolete)
4. Nickel Smelting Technology
23

24. Nickel Project Owner Country % Ni KT Ni Process
Cerro matoso BHP-B Colombia 2.3 41.6 RKEF
Codemin Anglo Brazil 2.1 9.1 RKEF
Doniambo SLN/Eramet New Caledonia 2 51.1 RKEF
Falcondo Falcon Bridge Dominican Rip 1.14 18.8 RKEF
Larymna Larco SA Greece 1.10 19 RKEF
Loma d NIquel Anglo Venezulea 1.6 10.9 RKEF
Pomala PT ANTAM Indonesia 1.58 17.6 RKEF
Kavadarci Cunico F.Y.R.O.M 2 15 RKEF
Sorowako Vale Inco Indonesia 2.10 72.4 RKEF
Murrin Murrin Mineral Resources Australia 1.43 30.5
Moa Bay Cuba 1.5 31.5
Fe –Nickel Production in world-
24

25. FE –NI PRODUCTION IN GREECE-
Larco is the Fe-Ni producer in Europe. 13th Largest Nickel
production in world. Covers more than 6% of the annual
demand in Europe. Ni production is 19000 tons per year(Avg
Ni content Fe-Ni 20%).
Laterite ore Production in Greece(tonnes)-
2010 2011 2012 2013 Total
Production
2200000 2600000 2300000 2200000 85000000
Mines Annual
Production(tonnes)
Average Ni Content (%)
Evia Mine 1.2-1.5 million 1-1.03
Ag. Ioannis mine 700,00 1.05-1.1
Kastoria Mine 250,000-300,000 1.3
Servia Lignite mine 350,000 1.2
25

26. KEY FACTS OF RESOURCES-
Sample Evia mine(55% w/w) Ag . Ioannis
mine(30% w/w)
Kastoria
mine(15% w/w)
SiO2 28.2 18.6 32.2
Al2O3 7 10.9 2.9
Fe2O3 47.5 45 24.8
Fe Total 33.2 31.4 7.2
Cr2O3 3.1 2.7 1.4
MnO 0.04 0.04 0.01
MgO 3.2 4 15.4
Ni 1.03 1.05 1.3
Co 0.05 0.06 0.06
S 0.4 0.45 0.45
Cao 3 6.6 1.45
LOI 5 7.5 12.5
Mineralogical and chemical composition of Larco Laterite Ores(% wt)
26

27. Fe-Ni Production Process
Handling Of Raw Materials
Pre-heating and Pre
Reduction in Rotary Kilns
Electric Furnace Reductive
Smelting
Enrichment-Refining in OBM
type Converters
Fe Ni Specifications
Chemical
Element
Content
Ni 17-25%
Co 0.75-1.00%
As 0.15% max
P 0.02% max
S 0.15% max
Cu 0.10% max
C,Mn,Si,Cr Traces
27

28. Flow Chart of FeNi Production in Larco
Oxygen Bottom Maxhuette-Oxgen bottom Blow Process 28

29. Material and Energy supply (Disel,electricity,electrodes,coke,Pellet,etc)
Waste Management Utilization
Field
Operations
• Ore Mining
and
Beneficiation
Plant
Operations
• Feed
Operation
Plant
Operations
• Smelting and
Refining
Rotary
Kilns
EF Furnace OBM Converter
Raw Materials Stockpiles
Pellet
Dust
Collector
29

30. Stage Input Unit Value
Ore Mining and Mineral
Beneficiation
Electricity
Disel
kWh/t ore
Litre/t ore
4.8
2.4
Ore preparation
Electricity
Cement
kWh/t ore
T/t Fe Ni
21.8
0.25
Smelting and Refining
Lignite
Coal
Carbon Electrodes
Lime
Oxygen
Electricity
T/t Fe Ni
T/t Fe Ni
Kg/t Fe Ni
Kg/t Fe Ni
Litre/t Fe Ni
kWh/t Fe Ni
2.84
2.63
63
74
210
10286
Input Inventory Data-
Functional Unit: 1 t of FeNi product (20% Ni)
30

31. THE EFFECT OF GANGUE MINERALOGY ON THE
DENSITY SEPARATION OF LOW GRADE NICKEL ORE
 Density separation is widely used to pre concentrate
minerals and reject unwanted gangue. For base metal
sulfide ores, dense medium separation(DMS) is used to
separate the sulfide minerals, which are relatively dense.
 After DMS it is treated in Flotation . Overall upgrade of
Ni from 0.4 to 0.7% Ni in the flotation sample as a
recovery of 87%.
 The efficiency of DMS according to the characteristics of
the ore .For low grade ores with complex mineralogy, the
properties of the gangue minerals are important factor that
determine the behavior of the ore during the separation.
31

32. The sink-float analysis results on the head sample indicate that, at
a density cut-point of 3.0, 48 mass % of the ore reported to the
sinks and 52% to the floats(Figure-1) . For Pentaldite Ore
Figure 1 Washability curve
32

33. The Ni grade was measured at 0.4% and the cumulative grade achieved at Pentalandite a cut-
point SG of 3.0 is 0.74% at a recovery of 83%. This density cut-point was chosen for the
DMS test work in order to maximise the waste rejection while obtaining a low Ni grade in
the overflow(Figure-2) .
Figure 2 Cumulative grade and recovery curves calculated for pyrrhotite and pentlandite
from the sink-float analysis 33

34.  In Nkomati mine where initial mining activity was centered on
the Ore. More recently the mining has been focused on lower
grades ores. Average Ni and Cu ores grade are 0.66 to 0.68%
and 0.22 to 0.44% respectively.
 The flow sheet of Nickel Production.
 A pentlandite grade of approximately 2% should be present in
the underflow, with a recovery of 83%. The pyrrhotite grade is
estimated at 12%, with an 88% recovery.
34
Grinding 300 micron

35. DMS TEST WORK AT A CUT POINT OF 3
The nickel Grade and Recoveries, as well as mass
distribution of the bulk sample calculated
Stream No Stream Name Mass(%) Ni Grade(%) Ni Recovery
(%)
1 ROM 100 0.43 100
2 -12mm+1mm 84 0.39 76
3 -1mm 16 0.62 24
4 DMC Overflow 44 0.13 13
5 DMC
Underflow
50 0.67 63
Mass,Grde,Recovery Information at different Point of the Flow Sheet-
Fraction Mass(%)
Grade (%) Recovery( %)
SSs Cc
Sinks 48 5.63 0.23 0.67 85 68 83
Float 52 0.95 0.10 0.13 15 32 17
Total Feed 100 3.20 0.16 0.39 100 100 100
S Cu Ni NiCuS
35

36. Nickel
Resources
Source Ni Fe Cu SiO2 Al2O3 MgO Others
Nickel Ferrous
Serpentine
Moreah
Assam
0.51 7.86 ------ 33.84 ----- 33.14 --------
Do Ranakpur
Rajasthan
0.26 5.75 38.45 1.83 37.18 16.19LOI
Nickel Ferrous
Laterite
Badamphar
Odisha
0.34 29.4 15.5 22.4 3.4 Cr2O3
0,27 V2O5
Do (Dense) Sukinda
Odisha
0.62 39.5 0.02 16.5 14 1.2 1.85Mn
Do(light) Sukinda
Odisha
1.41 47.04 6.8 12.36 1.1 2.9 MnO
Copper
Tailings
I.C.C.
Ghatsila
0.073 9.33 0.17 59.7 13.94 ------- 1.45 S
1.27 P2O5
Nickel Resources and Their Chemical Analysis in India-
36

37. Sukinda Chromites Over Burden Analysis By NML-
The average nickel concentration in the COB ore of Sukinda lies in the
range of 0.4-0.7%. The existing deposit of COB ore in the Sukinda valley
has been estimated to he around 140 million tonnes.
Process for Nickel Enrichment- COB ore of Sukinda valley is a
high silica matrix. Present nickel enrichment process consists of primarily
three stages.
Neutralisation
Stage I : Digestion with acid/ Combination of acids, HCI, HNO3
and H2SO4.
Stage lI Neutralisation with alkali. Na2CO3 and NaOH.
Stage III : Calcination at 900°C
Oxides of
Ni,Co,Cr,Fe
Hydroxides of Ni
Co,Cr, and Fe
Leach liquor of Ni,
Co,Cr, and FeRaw Nickel Ore
Ni-0.4-0.7%
I
Digestion
II
III
Calcination
900 degree centigrade
37

38. Parameters Optimized Value
COB ore 500 mg
Fineness -44 mesh
Hcl Concentration 50ml 12N
HNO3 Concentration 50 ml 14 N
H2SO4 Concentration 100 ml 36 N
H20 500 ml
Digestion time 3 hr
Temperature 100 degree Centigrade
Optimized Parameter with reference to extraction of Nickel-
38

39. Final product :-
The final product after the calcination was essentially a mixed oxide of Fe,
Ni, Cr, Co and other trace elements like, Al, Mn,Zn, Na. Ca etc. Complete
analysis of a typical final product is given in Table .
Element/Radical Content(%)
LOI 0.11
SiO2 0.13
Fe2O3 92.12
NiO 2.54
Cr2O3 1.75
CoO 0.14
Al2O3 1.21
MnO 1.42
ZnO 0.38
Na2O 0.67
X-ray diffraction of the final product indicated that it consisted of two phases
Fe2O3and nickel ferrite,NiFe2O4. It could be possible that the final product
consisted of a magnetic and a non magnetic phase
Complete Analysis Of Final Product-

40. Fe2O3 constituted the nonmagnetic fraction while NiFe2O4 made for the
magnetic fraction. This opened up the possibility of further nickel
enrichment by separating the magnetic and non-magnetic fraction
through magnetic separation. It was calculated from chemical analysis
assuming all the nickel were converted into NiFe2O4 the percentage is
9.37% . The process is not energy intensive and generates valuable by-
products that have ready market in the country. The process is
environment friendly and does not waste and effluent disposal problems.
Sukinda Chromite Ore Mines 40

41. 30
15
11
7
7
6
5
5
4
4
2 2 2
World Nickel Reserve
Ausralia
New Caledonia
Brazil
Rusia
Cuba
Other
Indonesia
South Africa
Canada
China
Madagascar
Philipines
Dominan Republic
41

42. 0
100
200
300
400
500
600
700
800
2007 2008 2009 2010 2011 2012
Africa
Asia
Oceania
America
Europe
Global Nickel Production in MT
42

43. 34
20
13
7
7
5
5
5
1.2
Nickel Uses in Different Sector
Transport/Defence
Fabricated Metal
Electric Equipment
Petroleum Industry
Chemical Industry
Construction
household
Appliances
Industrial
Machinery
Other
43

44. 65
3.9
0.8
7.3
8.3
5.3
2.7
2.9 0.5
0.9
2.4
Estimate Use of Nickel 2014
Stainless steel
Super alloys
Coinage
Other nickel alloy
Plating
Other steel alloys
Foundry
Batteries
Catalyst
Other Chemical
Other
44

45. Nickel Uses
45

46. 46

47. 47
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