Nickel Sulfate Dissolution Process for Higher Throughput
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Solution Overview
Problem
Existing methods for producing nickel sulfate solution face challenges such as low throughput, equipment deterioration due to thermal shock, and high production costs, particularly in the production of lithium nickel composite oxide for batteries.
Innovation Solution
A two-step continuous dissolution process using a leaching tank and a leaching adjustment tank, where the first tank maintains a high free sulfuric acid concentration for rapid nickel dissolution, and the second tank adjusts nickel concentration and reduces free sulfuric acid, allowing continuous operation without enlarging equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a simple continuous dissolution tank is used with low free sulfuric acid concentration, then the dissolution rate is low, but the equipment size and initial investment are reduced
Solution Approach 1:
The dissolution process is divided into two separate tanks: a first dissolution tank for initial nickel dissolution and a second dissolution tank for completing the dissolution. This segmentation allows each tank to be optimized for its specific function, enabling continuous operation with smaller individual tank sizes while maintaining high overall dissolution rates.
Solution Approach 2:
The system achieves continuous dissolution by having the first dissolution tank operate continuously with fresh sulfuric acid while the second dissolution tank processes the solution further. This continuous operation eliminates idle time between batches and maximizes throughput without requiring oversized equipment.
2Quantity of substance
If the tank is enlarged to lengthen the retention time, then the nickel solution concentration reaches the target extent, but a large space and large equipment are required and initial investment increases
Solution Approach 1:
The concentration achievement process is segmented across two tanks: the first tank performs rapid initial dissolution with high sulfuric acid concentration, and the second tank completes the concentration adjustment. This allows the target concentration to be achieved without requiring a single large tank with extended retention time.
Solution Approach 2:
The system changes the sulfuric acid concentration parameter between tanks - the first dissolution tank uses high free sulfuric acid concentration for rapid dissolution, while the second tank adjusts the concentration to achieve the target nickel sulfate concentration. This parameter variation enables efficient concentration achievement in smaller equipment.
3Productivity
If batch processing is used with simple dissolution process, then the process is simple to operate, but the throughput per equipment is small due to repeating cycles of introducing raw material, dissolution, and draining
Solution Approach 1:
The system transitions from batch processing to continuous processing by implementing two dissolution tanks that operate in sequence. The first tank continuously receives nickel briquettes and sulfuric acid, while the second tank continuously processes the solution, eliminating the need to stop for material introduction and draining operations.
Solution Approach 2:
The first dissolution tank performs preliminary dissolution of nickel briquettes with fresh sulfuric acid before the solution moves to the second tank for final concentration adjustment. This preliminary action allows the main processing tank to focus on completion rather than starting from scratch each cycle.
4Productivity
If temperature is raised for dissolution, then the dissolution rate increases, but thermal shock and equipment deterioration occur due to repeated high temperature and room temperature cycles
Solution Approach 1:
Instead of changing temperature to increase dissolution rate, the system changes the chemical parameter - using high free sulfuric acid concentration in the first dissolution tank to achieve rapid dissolution at moderate temperatures. This avoids thermal cycling while maintaining high productivity.
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 increases throughput, reduces thermal shock, and extends equipment life, ensuring stable production of nickel sulfate solution at target concentrations, suitable for lithium nickel composite oxide production.
Implementation Method 1
dissolving the nickel briquette to obtain a primary nickel sulfate solution
Implementation Method 2
dissolving the additionally introduced nickel briquette with free sulfuric acid in the primary nickel sulfate solution
Data Source
AI summary
Provided is a production method and a production apparatus that increase a throughput of nickel sulfate per equipment. A first dissolution step I of introducing a nickel briquette, sulfuric acid, and water to a leaching tank (1) and dissolving the nickel briquette to obtain a primary nickel sulfate solution, and a second dissolution step II of introducing the primary nickel sulfate solution and additionally introducing a nickel briquette to a leaching adjustment tank (2) and dissolving the additionally introduced nickel briquette with free sulfuric acid in the primary nickel sulfate solution to obtain a nickel sulfate solution are executed in this order. With the leaching adjustment tank (2) having a role as a concentration adjustment tank that increases a nickel concentration and decreases a free sulfuric acid concentration, and the leaching tank (1) supplied with the sulfuric acid and the water in addition to the nickel briquette, a continuous dissolution is achievable without increasing a retention time and without unnecessarily enlarging the equipment.