ABSTRACTAustralia has large reserves of limonite and clay-based laterites that are currently underutilized. This review summarizes the latest nickel laterite upgrading studies reported in the literature which use physical beneficiation – only studies reported after the most recent review in 2015 included – as well as high-temperature methods involving oxidation/reduction roasting (with and without additives), sulphidation, and other high-temperature methods. The focus of this review is on upgrading limonite ores, but studies using other types of laterites are also discussed for comparative purposes. Oxidative roasting has proven to be ineffective but producing a magnetic phase by reduction roasting then magnetically separating it from gangue minerals has produced nickel grades and recoveries of up to 14% and 99% respectively with limonite ores. The choice of reductant has negligible effect although hydrogen reduction is predicted to occur at slightly lower temperatures and recoveries are slightly lower compared with carbon-based reductants. The addition of sulfurous compounds improves agglomeration of ferronickel particles, increases the nickel grade and recovery. The highest recovery of 97.91% (grade 13.62%) was reported when sulfur was used as an additive during the roasting of a limonite ore with coal and limestone at 1400°C for 6 h. The results show reduction roasting followed by magnetic separation is effective for upgrading nickel ores, but challenges with this technology are the potentially high reagent usage and temperatures required. The economic feasibility for processing limonite ores via this route is not clear and should be investigated further.KEYWORDS: Reduction roastmagnetizing roastsulphidationmineralogyAustralian laterites Disclosure statementNo potential conflict of interest was reported by the author(s). 

Nickel Laterite Beneficiation and Potential for Upgrading Using High Temperature Methods: A Review

Nickel recovery in ferronickel concentrate by green selective reduction of nickel laterite

This study focused on the preparation of high-grade ferronickel concentrate, the behavior of efficient migration and the polymerization of ferronickel particles during reduction roasting, by adding calcium fluoride and a ferronickel concentrate to low-grade laterite ore from Yunnan. The effects of temperature, holding time, reductant content, ferronickel concentrate content and magnetic field intensity on the preparation of the ferronickel concentrate were studied and the optimum conditions were determined as follows: 30% ferronickel concentrate (metal Ni-4.68%, metal Fe-45.0%), 8% coal, 7% calcium fluoride, reduction temperature of 1250 °C, reduction time of 60 min and the intensity of magnetic separation is 150 mT. The proportion of nickel and iron in ferronickel concentrate was 88.7% (metal Ni-8.62%, metal Fe-80.1%), and the recovery efficiency of nickel and iron are 98.8% and 82.4%, respectively. X-ray diffraction and scanning electron microscopy indicated that ferronickel-concentrate, as an activating agent, improved the aggregation effect of ferronickel particles. The efficient migration and polymerization of ferronickel particles in the ore significantly increased the size of the ferronickel particles with additives, therefore a high-grade ferronickel concentrate was prepared, and the reduction and recovery efficiency of laterite nickel ore was improved.

Migration and Aggregation Behavior of Nickel and Iron in Low Grade Laterite Ore with New Additives

As the global demand for nickel transitions from ferronickel to nickel sulfate for batteries, the nickel sulfide ore reserves are becoming increasingly more difficult to mine. Although, the mining of the nickeliferous laterite ores is much simpler, the extraction of the metal is more challenging, with limited process options. Furthermore, the current processing techniques are costly and have environmental issues, resulting in the need to develop alternative technologies through laboratory research and pilot plant testing. In this paper, firstly, an overview is provided of the composition plus mineralogy of both the limonitic and the saprolitic nickeliferous laterite ores and of the current commercial techniques that are employed to process these ores. Secondly, the pyrometallurgical research work reported in the literature on the production of a nickel concentrate by selective reduction followed by magnetic separation is reviewed. The main objectives are to achieve a high nickel recovery and to produce a concentrate with a high nickel grade. Thirdly, the role of additives, in particular the sulfur-containing species, is evaluated. Fourthly, the main issues involved in the processing of these ores and of particular importance, the areas that require further research and development are discussed. Finally, the potential of these new developing processes to replace the current commercial operations is assessed. 

Solid state reduction and magnetic separation of nickeliferous laterite ores: Review and analysis

Effect of sodium sulfate and sodium chloride in two-stage thermal upgrading of low-grade Nickel Lateritic Ore

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Effect of sodium sulfate and sodium chloride in two-stage thermal upgrading of low-grade Nickel Lateritic Ore