Game changer for nickel processing
Hannah Vickers Wednesday, 29 May 2013
D
IRECT Nickel is looking to change the mining industry by providing a low-cost, environmentally friendly process to treat nickel laterites. MiningNewsPremium.net was at the official pilot plant opening in Perth on Friday.
Direct Nickel managing director and CEO Russell Debney at the official launch of the company's test plant. Courtesey of Direct Nickel.
The revolutionary process, which is being tested at CSIRO’s Australian Minerals Research Centre at Curtin University in Western Australia, uses nitric acid and is capable of processing nickel laterites easily and with very little waste.
Most nickel in the past has been from sulphides, which are processed using standard flotation techniques but laterites are very different.
Direct Nickel chief executive officer and managing director Russel Debney said the existing laterite processes were known for their high intensity.
“Not only that, the processes that are currently available are selective so that a process to treat the iron-rich limonite section of a laterite would be a different process from that used to treat the magnesium-rich saprolite layer,” he told MiningNewsPremium.
“The DNi process treats both in the same flow sheet.”
Direct Nickel project manager and technology head Graham Brock said the process was needed to open up the nickel laterite deposits around the world.
“Unfortunately most of the easy sulphides have been found and finding new ones is getting harder and harder,” he said.
Companies waiting for an effective way to treat laterites won’t have to wait much longer.
In the Direct Nickel process, material is crushed to around 2mm then conveyed into leaching tanks where it will sit for approximately four hours at 100 degrees Celsius before separating out anything that didn’t dissolve in the nitric acid from the solutions.
Iron, aluminium, cobalt and nickel are all produced from the process, along with magnesium nitrate which is processed into magnesium oxide and can be sold as a by-product.
The nitric acid left at the end of the process is sent back through pipes to the first leaching tank to start its work again, with more than 90% of the acid recycled.
As a result, the amount of reagent left in tailings is very small compared to alternative processes and will be easily neutralised.
In addition to Direct Nickel and CSIRO stakeholders, WA Mines and Petroleum Minister Bill Marmion and Chilean ambassador Pedro Pablo Diaz Herrera were on the scene for the opening.
“I must take my hat off to everyone here involved in this process,” Marmion said.
Speaking with MiningNewsPremium, Marmion said the development of the Direct Nickel process was important for the state, especially because of how inexpensive it would be to run.
“It actually opens up a whole lot of extra resources for Western Australia and the world,” he said.
Partnering with CSIRO has given Direct Nickel the ability to run the test plant for a full year and give the company time to get a real feel for the process, according to Brock.
“If we did the same exercise in a commercial facility, we’d probably spend all the money we’re going to spend in a year here in a month and we just would not get the data that is needed to demonstrate and to confirm all the things we know about this process,” he said.
“So it’s a fantastic opportunity to be able to run this plant here for a whole 12 months.”
Having the plant running for a while also gives the company an opportunity to greet sceptics as well as potential investors.
Brock said roughly 60 visitors had come to the plant in March and April and of the 40 who expressed interest, 20 might be serious about getting involved.
The pilot plant, which has been running since January and is processing around 1 tonne per day of ore, will operate through October.
“We’re going to learn so much,” Brock said, while taking stakeholders on a tour of the facilities.
“If we’re going to find a problem, we’ve got time to do it.”
The plant has already processed ore from Indonesia before recently starting work on Brazilian samples without any difficulty.
Should things go according to plan, the first commercial Direct Nickel plant will be operational by 2017.
“The world has been waiting a long time for this breakthrough and it is literally weeks and months away,” Debney said.
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