Nickel Laterite Ore Agglomeration with Controlled Acid
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Solution Overview
Problem
Existing agglomeration methods for nickel laterite ores using concentrated sulfuric acid result in friable agglomerates that cause heap blockages and excessive dissolution of unwanted impurities, limiting heap leaching efficiency and increasing costs.
Innovation Solution
Adjusting the moisture content of nickel laterite ore to between 5% and 30% and using a sulfuric acid containing agglomerating solution with a concentration of 140 to 280 g/L, allowing for optimal agglomeration that improves permeability and structural integrity of the ore heap, enabling higher heap formation and more efficient metal recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If concentrated sulfuric acid is used for agglomeration, then ore mineral breakdown is improved, but agglomerate structural integrity deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the sulfuric acid concentration within 140-280 g/L and moisture content within 5-30%, transforming the agglomeration process from using concentrated acid to using controlled-concentration acid solutions, thereby resolving the contradiction between mineral breakdown and structural integrity
Solution Approach 2:
The patent utilizes phase transitions through controlled evaporation of moisture from the agglomerating solution, allowing the solution to transition from liquid to vapor phase, which concentrates the acid in situ and promotes binding agent formation without requiring initial concentrated acid application
2Productivity
If concentrated acid solution is used for agglomeration, then leaching efficiency is improved, but heap blockages occur due to friable agglomerates
Solution Approach 1:
The patent changes the concentration parameter of the agglomerating solution to 140-280 g/L sulfuric acid with 5-30% moisture, creating agglomerates with optimal strength that maintain heap permeability while achieving effective leaching, thus resolving the contradiction between leaching efficiency and heap blockage prevention
3Productivity
If concentrated acid is used for agglomeration, then metal extraction is improved, but dissolution of unwanted impurities increases
Solution Approach 1:
The patent applies parameter changes by controlling acid concentration at 140-280 g/L rather than using concentrated acid, achieving sufficient metal extraction while limiting excessive impurity dissolution, thus resolving the contradiction between metal extraction efficiency and impurity loss
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enhances heap leaching efficiency, increases output rates, and reduces costs by producing agglomerated ore that maintains structural integrity and allows for higher heap formation, leading to improved metal recovery rates.
Implementation Method 1
the sulfuric acid has enough chemical reaction time to attack the nickel containing minerals, partially dissolve some of the ore
Implementation Method 2
remove some of the contained water (by air evaporation) and allow basic sulfates and/or silicates, or silica gel to be precipitated
Implementation Method 3
allow basic sulfates and/or silicates, or silica gel to be precipitated and form into a binding agent to keep the remaining ore particles together
Implementation Method 4
the generation of heat from the exothermic reaction of the aid and the small amount of moisture present in the ore. This can result in better break-down of the ore minerals
Data Source
AI summary
A method of agglomerating a nickel laterite ore comprising the steps of: i) feeding a nickel laterite ore material to be agglomerated into an agglomeration circuit; and ii) adding a sulfuric acid containing agglomerating solution to the ore material in the agglomeration circuit to provide an agglomerated ore material, wherein the acid concentration of the agglomerating solution is between 100 to 400 g/L.