Nickel Ore Concentrate Processing via Microwave-Assisted Acid Leaching
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Solution Overview
Problem
Current methods for processing laterite nickel ore are unable to efficiently extract nickel from the ferruginous and saprolite portions of the ore, leading to waste and environmental issues, as well as high operating costs and CO2 emissions.
Innovation Solution
A method involving scrubbing, sorting, magnetic separation, and chemical processing using hydrochloric acid and microwave irradiation to produce a nickel ore concentrate, which can then be processed to recover nickel, cobalt, and other valuable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional processing methods are used on laterite nickel ore, then sulfated nickel deposits can be processed, but ferruginous and saprolite portions cannot be efficiently extracted
Solution Approach 1:
The patent applies high-pressure acid leaching (HPAL) which changes the processing parameters (pressure, temperature, acid concentration) to enable extraction of nickel from ferruginous and saprolite portions that cannot be processed by conventional methods. This parameter change allows the system to handle diverse ore types and recover nickel that would otherwise be lost.
2Loss of substance
If HPAL method is used to process laterite ore, then nickel can be recovered from ferruginous and saprolite portions, but high operating costs and CO2 emissions occur
Solution Approach 1:
The patent implements a closed-loop system where process water and chemicals are recycled and reused within the processing circuit. This self-service approach reduces the need for fresh water and chemical inputs, thereby reducing the energy required for material handling and processing, which in turn reduces CO2 emissions while maintaining high nickel recovery.
3Loss of substance
If HPAL method is used to process laterite ore, then nickel can be recovered from ferruginous and saprolite portions, but high operating costs occur
Solution Approach 1:
The patent designs a multi-functional processing system that can handle multiple ore types (sulfated, ferruginous, and saprolite) using the same HPAL infrastructure. This universality allows the facility to process lower-grade ores that would otherwise be discarded, maximizing nickel recovery while spreading fixed costs across diverse feedstocks, thereby reducing overall operating costs.
4Ease of manufacture
If conventional flotation methods are used, then sulfated nickel deposits can be processed, but ferruginous and saprolite portions are wasted
Solution Approach 1:
The patent transitions from conventional flotation (ambient pressure, mechanical separation) to high-pressure acid leaching (high pressure, chemical dissolution). This parameter change enables the processing of ferruginous and saprolite portions that are resistant to conventional methods, converting them into recoverable nickel while maintaining operational feasibility through automated control systems.
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
This method enables the recovery of previously untapped nickel ores, reduces fossil fuel consumption and CO2 emissions, and efficiently extracts economically relevant materials, thereby addressing environmental and economic challenges in the nickel ore processing industry.
Implementation Method 1
heating the nickel ore concentrate until converting over 90% of the nickel and cobalt contained in the nickel ore concentrate into its soluble chloride form
Implementation Method 2
heating the nickel ore concentrate until converting over 90% of the nickel and cobalt contained in the nickel ore concentrate into its soluble chloride form
Implementation Method 3
magneticaly sorting the coarse fraction for obtaining a magnetic fraction
Data Source
AI summary
The present invention refers a method of recovering materials derived from nickel ore, involving a method of obtaining nickel ore concentrate and a processing method of said concentrate, whereby nickel ore can be processed in an efficient and ecological manner, and residues and materials currently untapped can be recovered from this nickel ore.