Title of Invention	A PROCESS FOR EXTRACTION OF NICKEL FROM LOW GRADE CHROMITE ORE
Abstract	The present invention is a process for the extraction of nickel chromite ore containing 0.6 to 0.9 % nickel, said process comprises of crushing, drying and grinding of low grade Chromite Ore to obtain +100 to -400 mesh B.S.S. with 85% -200 mesh B.S.S., subjecting the crushed ore to reduction-roasting with or without pre-mixing of oil, leaching the reduced material in an ammonia-ammonium carbonate solution using oxygen or compressed air at elevated pressure of 0.2 to 1.5 kgs/cm2, precipitating the dissolved nickel as basic nickel carbonate and co-precipitating cobalt and recovering ammonia as well as carbon dioxide for recycle and obtaining a magnetic fraction through a wet magnetic separation technique which is suitable for use in low phosphorous iron production.

Title of Invention

A PROCESS FOR EXTRACTION OF NICKEL FROM LOW GRADE CHROMITE ORE

Abstract

The present invention is a process for the extraction of nickel chromite ore containing 0.6 to 0.9 % nickel, said process comprises of crushing, drying and grinding of low grade Chromite Ore to obtain +100 to -400 mesh B.S.S. with 85% -200 mesh B.S.S., subjecting the crushed ore to reduction-roasting with or without pre-mixing of oil, leaching the reduced material in an ammonia-ammonium carbonate solution using oxygen or compressed air at elevated pressure of 0.2 to 1.5 kgs/cm2, precipitating the dissolved nickel as basic nickel carbonate and co-precipitating cobalt and recovering ammonia as well as carbon dioxide for recycle and obtaining a magnetic fraction through a wet magnetic separation technique which is suitable for use in low phosphorous iron production.

Full Text	A PROCESS FOR EXTRACTION OF NICKEL FROM LOW GRADE CHROMITE ORE Technical Field The present invention relates to a process for the extraction of nickel from low-grade chromite ore. Particularly, the present invention relates to a process for the extraction of nickel and cobalt from low-grade chromite ore. Background Art Nickel is a strategic metal which finds use in steel, chemical, cryogenics, food processing, and aerospace industries. The present consumption of nickel in India is estimated to be -20,000 tons per annum (tpa), and its annual growth rate is 5-7%. With rapid industrial growth, the demand for ferro-nickel is likely to exceed the projected figure. Most of the demand for nickel is presently being met through imports incurring foreign exchange worth of -Rs.1000 crores per year. Cobalt is also a strategic metal and its demand in India is -150 tpa. In the present process cobalt is recovered as a by-product. The only nickel deposit in India is in the Sukinda region of Orissa. i he resources are estimated to be approximately 32 million tons in lateritic deposits oi Sukinda region having ~1% nickel in the non-chromite and approximately 200 million tonne as low-grade chromite ore having an average of 0.7% nickel. For any commercial exploitation of Sukinda deposit for reasonable period of time low grade chromite ore will be the largest resource. Large stock piling of low-grade ore (which cannot be exploited for recovery of chromite) in Sukinda region has lead to environmental problem. It destroys natural forests around the mines and may contribute hexavalent chromium to water stream. In the world, presently there is no operating plant using such low-grade nickel containing materials particularly the lowgrade chromite ore. The major oxide ore deposits are in Indonesia, Phillipines, Cuba, Dominical Republic, Colombia, and New Caledonia. While the Colombian ore is perhaps the richest with more than 2.9% nickel, the poorest ores being commercially used are from Nicaro, Cuba and Kazakstan, containing ~ 1.1% nickel. The discarded low grade chromite ore generated at Sukinda region of Orissa, India contains in an average only -0.7% nickel. Reference may be made to one of the conventional methods for dissolution of nickel from these laterites by acid pressure leaching for which a commercial plant at Moa Bay is in operation (E.T Carlson, C.S Simons, Journal of Metals, 1960. 198(3), p 206- 213) and another plant based on pressure leaching-solvent extraction has been set up in Australia. The other method is by reduction-roasting followed by oxidative ammoniacal leaching and is named as Caron's process (M.S. Caron, United State Patent 1.487,145. March 18, 1924). A number of commercial plants including one at Nicaro. Cuba and the other at Greenvale, Australia are in operation. Many International Conferences have since been devoted to the advances in metallurgy of nickel and cobalt (e.g., International Laterite Symposium, AIME-SME Annual Meeting, New Orleans, February 1979, International Symposium on Nickel Metallurgy held at Montreal 1986, Symposium on Metallurgy of Nickel and Cobalt, held at Arizona, Jan 25th to 28lh, 1988, Nickel and Cobalt 97-International Symposium held at Sudbury, Ontario, Canada during Aug. 17-20 1997). The most widely commercially applicable process is still the Caron's process (M.H. Caron, Journal of Metals, 1950, vol. 188(1), p 67-90). In this process the nickel ore is reduced and treated with ammonia-ammonium carbonate solution in the presence of compressed air. During leaching the reduced nickel and cobalt form soluble amine complexes and the reduced iron comes first to solution as ferrous amine and subsequently gets oxidized to hydrated ferric oxide. The time required for almost complete dissolution of desired metals and precipitation of iron in the commercial plants is about six hours. Although most of the nickel in the world is present as oxide, due to ease of beneficiation, sulphides of nickel are the major source of nickel production. But with depletion of good grade sulphide ore, slowly the use of oxides for nickel extraction is increasing. Currently, roughly about 40% of the nickel is produced from oxide ore. Drawbacks of the earlier processes (i) All the processes for extracting nickel and cobalt known as of date use nickel ore containing -1.1 to 1.5% Ni. The low-grade chromite ore containing 0.5 to 0.9% nickel has never been used in any process in the world following leaching with ammonia - ammonium carbonate solution, (ii) The results on continuous test work are not available for low-grade chromite ore. ( i i i ) In all the existing plants oil is mixed with the dried ore prior to feeding to the furnace for reduction, and nowhere in the world reduction step has been carried out without mixing oil to the ore prior to reduction. ( i v ) The present plants use compressed air for oxidation and dissolution of nickel in the leaching reactors. The retention time of about six hours is required to complete nickel dissolution and iron precipitation. In order to reduce the retention time, no efforts have been reported. (v) The use of compressed air during leaching requires elaborate ammonia recovery system to minimize ammonia losses from the vent gases. (vi) The leach residues obtained after Ni recovery from the lateritic ore contains primarily magnetite. These residues are being discarded. No efforts have been reported for the utilization of these residues. Due to lack of information on utilization of low Ni containing material such as lowgrade chromite ore, studies have never been done to exploit this resource for the recovery of nickel and cobalt. Objects of the Present Invention: The main objective of the present invention is to provide a process for the extraction of nickel from low-grade chromite ore. Another objective of the present invention is to enhance leaching rate with gaseous oxygen. Still another object of the present invention is to use compressed air at elevated pressure in the range of 0.2 to 1.5 Kg./cm2 for reducing the retention time during leaching step. Yet another object of the present invention is to use gaseous oxygen at elevated pressure in the range of 0.5 to 1.5 Kg./cm2 for reducing the retention time during leaching step. One more object of the present invention is to utilize the leach residue for its magnetite content. Summary of the Present Invention: Accordingly, the present invention provides a process for extraction of nickel from low-grade chromite ore containing 0.6 to 0.9% nickel, the said process comprises the steps of: (a) crushing, drying and grinding the chromite ore to obtain crushed chromite ore having particle size ranging between 100 to 400 mesh British Standard Seive. (b) roasting the crushed chromite ore of step (a) at a temperature in the range of 600-800°C to effect reduction, (c) cooling the roasted ore; at a temperature less than 25°C (d) mixing the cooled reduced ore of step (C ) with a leaching solution containing ammonia and ammonium carbonate to form a slurry, passing compressed oxygen or air through the slurry at a pressure in the range of 0.2 to 1.5 Kgs.cm 2and aging the slurry for 45 minutes to 6 hours to effect leaching; (e) oxidizing the leached slurry of step(d) in presence of excess ammonia to obtain a pregnant leach solution and leach residue; (f) separating the pregnant leach solution from the leach residue by counter current decantation and washing the pulp with ammonia-ammonium carbonate solution; (g) stripping ammonia from the pregnant leach solution of step (f) to effect precipitation of dissolved nickel and cobalt in the form of their respective salts. Brief Description of the Accompanying Drawings: In the drawings accompanying the specification, Figurel represents the schematic block diagram of the process of extraction of nickel from chromite over burden. Figure 2 represents the process flow diagram for Section 100 (Crushing, Drying and Grinding), Figure 3 the process flow diagram for Section 200 (Reduction Roasting). Figure 4 (a) represents the process flow diagram for Section 300 (Leaching with Oxygen gas). Figure 4 (b) represents the process flow diagram for Section 300 (First Stage Leaching with Air). Figure 4 (c) represents the process flow diagram for Section 300 (Second Stage Leaching with Air). Figure 5 represents the process flow diagram for Section 400 (counter current decantation). Figure 6 represents the process flow diagram for Section 500 (BNC Precipitation, Ammonia removal and recovery). Detailed Description of the Present Invention: The present invention provides a process for extraction of nickel from low-grade chromite ore containing 0.6 to 0.9% nickel, the said process comprises the steps of: (a) crushing, drying and grinding the chromite ore to obtain crushed chromite ore having particle size ranging between 100 to 400 mesh B.S.S; (b) roasting the crushed chromite ore of step (a) to effect reduction; (c) cooling the roasted ore; (d) mixing the cooled reduced ore of step (c) with a leaching solution containing ammonia and ammonium carbonate to form a slurry, passing compressed oxygen or air through the slurry and aging the slurry for 45 minutes to 6 hours to effect leaching; (v oxidizing the leached slurry of ;,ii:p (d) in presence of excess ammonia to obtain a pregnant leach solution and leach residue; (t) separating the pregnant leach solution from the leach residue and washing the pulp with ammonia-ammonium carbonate solution, and (g) stripping ammonia from the pregnant leach solution of step (f) to effect precipitation of dissolved nickel and cobalt in the form of their respective salts. In an embodiment of the present invention the low-grade chromite ore contains 0.6 to 0.9 wt. % Ni, 0.034 to 0.044 wt. % Co. 43 to 53 wt. % Fe, 2.42 to 2.72 wt. % Cr2O3 and 6.9 to 8.8 wt. % Al2O3 and the rest being impurities. In another embodiment of the present invention, wherein in step (a), 85% of the crushed chromite ore have particle size of 200 mesh B.S.S. In yet another embodiment of the present invention, wherein in step (b), crushed lowgrade chromite ore is roasted in a multiple hearth furnace at a gas temperature in the range of 600 to 800°C to effect reduction. In still another embodiment of the present invention, the crushed low-grade chromite ore is fed to the multiple hearth furnace with or without premixing fuel oil. In one more embodiment of the present invention, the crushed low-grade chromite ore is reduced by passing CO / (CO+ CCO2) and H2 having a reduction potential of 0.2 to 0.6 through the multiple hearth furnace. In one another embodiment of the present invention, wherein in step (c), the roasted chromite ore is cooled to a temperature less than 250°C. In further embodiment of the present invention, wherein in step (d), the leaching solution contains 60 to 90 g/1 ammonia and 80 to 120 g/1 ammonium carbonate. In an embodiment of the present invention, wherein in step (d), the pressure of the compressed oxygen or air is in the range of 0.2 to 1.5 Kgs/cm2. In another embodiment of the present invention, if oxygen is used in step (d), the slurry is aged for 45 minutes to 2 hours. In yet another embodiment of the present invention, if air is used in step (d), the slurry is aged for 3 hours to 6 hours. In still another embodiment of the present invention, wherein in step (f), the pulp is washed with ammonia-ammonium carbonate solution using counter current decantation technique. In one more embodiment of the present invention, wherein in step (g), ammonia is removed from the pregnant leaching solution by passing steam through the same. in one another embodiment of the present invention, the ammonia removed from the pregnant leaching solution is recovered and re-used. In a further embodiment of the present invention, wherein in step (g), the dissolved nickel precipitates as basic nickel salt. In an embodiment of the present invention, the dissolved nickel salt precipitates as basic nickel carbonate (BCN). In another embodiment of the present invention, wherein in step (g), the dissolved cobalt co-precipitates along with nickel as cobalt salt. In yet another embodiment of the present invention, the leach residue obtained in step (0, is used for extracting magnetic fraction. In still another embodiment of the present invention, the magnetic fraction is obtained is separated by wet magnetic separation technique. In one more another embodiment of the present invention, the magnetic fraction thus obtained is used for production of low phosphorous iron production. The novelty of the present invention lies in the following factors: 1) Use of Low Grade Chromite Ore for extraction of nickel, cobalt and iron. 2) Reduction roasting without premix of additive such as oil. 3) Use of oxygen/air during leaching at an elevated pressure. 4) Generation of magnetite residue suitable for coal washeries 5) Generation of low phosphorous containing magnetite for low phosphorous iron production The schematic block diagram of the process is shown in Fig 1. The main steps of the process are divided into following steps. 1. Ore drying and grinding. 2. Reduction roasting 3. Ammonical leaching 4. Counter current washing and decantation 5. Basic nickel carbonate precipitation , ammonia stripping and recovery 6. Testing for residue utilization A pilot plant has been set up jointly by Council of Scientific and Industrial Research, (CSIR) and Hindustan Zinc Limited (HZL) at the premises of Regional Research Laboratory, Bhubaneswar 751013. The pilot plant used for carrying out the work for the production of nickel salt from low-grade chromite ore is divided into the following five sections. These are: Section 100: Ore Preparation Section 200: Reduction Roasting Section 300: Leaching Section 400: Counter Current Decantation Section 500: Precipitation of nickel salt The other utilities provided are: 1. Producer Gas Generator 2. Instrument Air Compressor 3. Reciprocating Air Compressor 4. Cooling Tower 5. Boiler 6. Fire Extinguisher The operating principles for each section are described below: Ore Preparation (Section 100, Step-1) The flow diagram for Section 100 (ore preparation) is shown in Fig 2. The raw material is stored in the storage area SY-101, which is an area at the ground level with suitable curbing on all four sides to avoid spread of material. SY-101 is housed inside a covered shed to avoid rain or water ingress. The raw material is loaded manually into container CN-101, mounted on a trolley TR-101. The trolley is placed below the overhead electric hoist EH-101. The electric hoist lifts the container CN-101 and unloads the raw material into a grizzley GR-101. The material with size -50 mm passes through GR-101 and is fed into the hopper H-101. The oversize material is manually broken and fed again to grizzley GR-101. The material collected in hopper H-101 is fed into a jaw-cum-roll crusher JC-101 through a vibratory feeder VF-101. JC-101 reduces the size of the raw material to -6 mm. The oversize (+ 6 mm) from jaw crusher JC-101 is fed to a roll crusher RC-101. The sized output from the combined unit of Jaw-cum-Roll crusher JC-101 and Roll crusher RC-101 is discharged on a belt conveyor BC-101 which feeds to a bucket elevator BE-101. The bucket elevator delivers the material to an overhead storage bin H-102, which discharges the material to a screw feeder SF-101. The discharge of SF- 101 is fed to a drum drier D-101. The material is dried co-currently in drum dryer D- 101 by passing products of combustion of o: the dryer. ST-102 provides oil to the burner - ed to the combustion chamber. This tank receives oil from the main oil storage tank. Air to the combustion chamber is provided by fan/blower B-101. The output from the dryer is dried material with 1-3% tree moisture and 10-11% bound moisture. The material from D-101 is collected in a hopper H-103. The dried material from hopper H-103 is fed into a ball mill BM-101 at the specified rate through a rotary valve RV-101. The rotary valve also prevents ingress of air to the ball mill when material is being fed into it. A blower B-102 supplies air to the ball mill which of air swept type. In the ball mill BM-101, the dried material is reduced in size to 85% -200 mesh B.S.S. The finer part of discharge from drum dryer D-101 goes directly to day storage bin H- 104 by bucket elevator BE-102 through a cyclone separator C-101 and BF-101. The discharge from ball mill BM-101 passes through a cyclone separator C-102, rotary valve RV-102, and collected in the day storage bin H-104 by bucket elevator BE-102. The gases/air containing solid particles which comes out of the dryer & ball mill passes through the cyclone separators C-101 and C-102, bag filters BF-101 and BF- 102 and gas/air is discharged through blowers B-104 and B-103 to the atmosphere through stacks STA-101 and STA-102 respectively. The storage bin H-104 has a capacity to store one day's requirement (-10 tons) of dried raw material. The material from H-104 is discharged into a trolley container CN-102A&B which is placed on a trolley TR-102A/B. CN-102A/B has a capacity of -0.5 tons. Oil (as and when required) is manually mixed with the ore and the trolley is pushed on rails below a hoist EH-102 which lifts the container and discharges the material into the hopper H-105 on top of MHF-20L From the hopper the material is delivered to screw conveyor SC-101 at the required rate. The rate of feeding to MHF- 201 can be varied by adjusting the valve provided in the discharge of hopper H-105. A rotary valve RV-103 is provided at the outlet of screw conveyer SC-101 for feeding of COB at a constant rate to MHF. This also avoids escape of flue gases from the MHF into the atmosphere. The oil storage tank ST-101 receives the oil from main oil storage tank and supplies oil to the combustion chamber of the MHF-201. Reduction Roasting (Section 200, Step-2) The flow diagram for reduction roasting is given in Fig. 3. The pre-processed raw material from section 100 (85% - 200 Mesh B.S.S. containing i free moisture) is fed into the Maniple Hearth Furnace MHF-201 from the hopper H-105. MHF-201 has a capacity to process 500 kg of raw material per hour. The MHF-201 is a 17-hearth furnace (0-16), with four rabble arms per hearth. The raw material in the MHF is heated by means of gases coming from the combustion chambers CC-201 A and B. The products of combustion chambers are fed into the MHF-201 through suitable ducting to deliver the gases at hearth numbers 15.13 and 1 1 . The two combustion chambers are located diametrically opposite to each other. The rabble arms are rotated by means of a central shaft which is air cooled. The cooling air to the shaft is supplied by blower B-202. The hot air after cooling the central shaft is used in the pre heating of hearths and is partly let out through the stack STA-201. The combustion chambers CC-201 A/B are supplied with Light Diesel Oil (LDO) from the oil storage tank ST-101 (ref Fig-2). The combustion air required is supplied by blower B-201. The burners of the combustion chambers are dual fuel fired type, with a provision to burn producer gas also. The oil supply to CC-201 A/B is measured by means of flow transmitters. The MHF-201 can be divided into three zones. The first zone comprising of hearths 0 to 3 is the ore-preheating zone. Hearths 4 to 14 comprise of the reduction roasting zone and hearths 15 and 16 comprise of the soaking zone. The total residence time in the MHF can be controlled by varying the shaft speed. The flue gases composed of CO, COo and H2 from CC-201 A/B come in contact with the feed material through hot gas ducts in the reduction roasting zone and the material gets reduced. The reducing atmosphere is maintained in the MHF-201 by additionally injecting LDO/fresh producer gas through nozzles provided in this zone. The rate of addition of producer gas can be measured by flow transmitter. The desired CO-CO2 ratio is maintained. The unreacted CO and Hi in the reducing gas are burnt in the preheating zone by injecting hot air which is provided through the shaft cooling blower B-202. The MHF- 201 is provided with nozzles for sampling both gas and solid at various locations. The temperature profile of the MHF-201 is measured and recorded by a multi-point temperature scanner. The hot flue gases at about 425°C are let out from MHF-201 from the top. Any solid carry over in the flue gases is recovered in the dust recovery system comprising of a multi cyclone separator C-201. The solids are re-introduced into MHF-201 through motorized rotary valve RV-201. The gases from C-201 are then passed through ventury scrubber VS-201 and demister S-201 before being discharged to the atmosphere by blower B-203. Water is circulated using pump P-201 in the ventury scrubber VS-201 and demister S-201 at a constant rate to cool and clean the exhaust gases. The reduced low-grade chromite ore from MHF-201 is discharged into a jacketed screw conveyer SC-201A. Cold water is circulated in the jacket for cooling the reduced low-grade chromite ore. The cooled material is further conveyed through another screw conveyer SC-201B into the quench tank SV-301. The temperature of the cooled material is less than 250°C. Leaching (Section 300, Step-3) In the leaching section there are two options namely (i) Use of oxygen during leaching at elevated pressure (ii) Use of compressed air at elevated pressure Leaching using gaseous oxygen at elevated pressure The process flow diagram for leaching with oxygen gas is shown in Fig 4 (a). The reduced ore after cooling in SC-201A&B is discharged continuously in a sealed atmosphere into the quench tank SV-301. The quench tank receives solution containing ammonia, ammonium carbonate and nickel through two streams separately from ST-301 by using pump P-304 (after cooling it to about 38°C in a double pipe heat exchanger E-301) and from storage tank ST-401 by using pump P- 401 (refer Fig.5). Make up ammonia-ammonium carbonate solution may be fed to the quench tank SV-301 from the solution preparation tanks SV-401/SV-502 using pumps P-507 and P-508 (ref. Fig.6) to obtain the required concentration of leachant. The coolant in E-301 is cooling water. In the quench tank SV-301 the hot solids are added to the quench liquor to form required slurry concentration with an outlet temperature of around 40°C. The quenched slurry is pumped to the first reactor, R-301A by pump P-301. The slurry overflows to reactor R-301B by gravity. Oxygen is supplied to both • the leaching reactors by maintaining the desired gauge pressure. Oxygen supply to the reactors is controlled by pressure control valves which are maintained at the desired pressure. The slurry, after leaching is transferred due to the pressure in the reactor R- 30IB to the leach slurry thickener TH-301A. The oxidizing ammonia leach is done in the presence of excess ammonia to prevent precipitation of nickel and cobalt as hydroxides, resulting in a pH of about 10-11 in the pregnant leach solution. The thickened underflow from TH-301A is pumped to the CCD section by pump P-302 to TH-401 A. The overflow from TH-301A flows by gravity to ST-301. The flow rates of quench slurry, leached slurry, and pregnant leach solution to the section for precipitation of nickel salt and to quench tanks are controlled through valves and the flows are indicated by transmitters/ indicators. As stated above part of the leach solution from the storage tank ST-301 is pumped to SV-301 through the cooler E-301. The other part of the leach liquor goes to filter press FI-301A &B by pump P-303. The filtrate is collected in storage tank ST-304 from where it is fed to the tower T-501 by pump P-305. Leaching Using Compressed Air at elevated pressure The procedure for leaching with compressed air is similar except that the number of reactors and thickeners are more for providing longer retention time. The flow diagrams for leaching using compressed air are shown in Fig 4 (b) and 4 (c). In case of air leaching, the leaching operation is carried out in two stages, the first stage consisting of four reactors R-301A to R-301D and the second stage consisting of three reactors R-301E to R-301G. The flow of slurry between the reactors within each stage is by gravity. The last reactor of the first stage R-301D discharges slurry by gravity into the first thickener TH-301 A, from where the underflow is pumped into the first reactor of the second stage R-301E. The clear solution overflowing from TH- 301 A is collected in the storage tank ST-301. A part of this solution is pumped to the quench tank SV-301 through a cooler E-301. Another portion of the leach solution is pumped to the BNC precipitation section (Section 500) through a batch filters FI- 301A & B for further processing. The filter is used to remove any residual solids from the leach solution. The thickened underflow from TH-301 A is pumped by P-302 to the first reactor R- 301E of the second stage leaching. From R-301E, the slurry flows to reactors R-301F and R-301G and finally to the thickener TH-301B by gravity. The clear solution from TH-301B is collected in storage tank ST-302 and a part of it is pumped to the quench tank and another part is recycled back to R-301E, by pump P-307. The underflow from TH-301B is pumped to the CCD section (sec. 400) by pump P-306. The vents are connected to a ventury scrubbing system. Counter Current Decantation (Section 400, Step- 4) In this section, separation of pregnant leach solution from leach residue and washing of the pulp with ammonia-ammonium carbo -olution is carried out using a series ol thicKeners TH-401A, B, C, D and E as >. in Fig.5. The washing of the leach residue is done counter currently. The underflow slurry is pumped from one thickener to another by pumps P-402 to P-405. Pump P-406 is used to discard the washed slurry from TH-405 to the tailings pond. The flow of slurry and flow of clear overflow from one thickener to another is as shown in the Fig.5. Precipitation of nickel salt and Ammonia Recovery (Section 500, Step- 5) The flow diagram for this section is given in Fig. 6. The leach solution containing dissolved nickel from the leach solution storage tank ST-304 is pumped by P-305 to the top of a stripping column, T-501. Steam is admitted at the desired pressure from the bottom of the column for stripping of ammonia and carbon dioxide from the pregnant leach solution. The descending solution is gradually depleted of ammonia until nickel precipitates as basic nickel carbonate (BNC). The dissolved cobalt also co-precipitates in this step. The mixed nickel and cobalt salt is precipitated in the column is discharged from the bottom at cooled with water circulation before pumping it to batch filter FI-501A/B. The cake from the filter is recovered, weighed and analyzed for nickel and other metals. The filtrate is collected in the storage tank ST-505 and pumped to the thickener TH-401E for washing of the final tailings coming from thickener TH-401D of section 400. The vapors from the tower T-501 are condensed in the heat exchanger E-501. The gases are cooled by cooling water circulation in it. The condensed liquid containing ammonia is collected in the condensate tank ST-502. The uncondensed vapors from E-501 are sent to an absorption tower T-502 for the recovery of residual ammonia. The gases are scrubbed with fresh water fed from the top of the tower T-502 and or by re-circulation of lean ammonia solution from ST-503. The vapors free of ammonia are discharged to the atmosphere. The ammonia solution from ST-502 is cooled in a water cooled double piped heat exchanger E-502 and is pumped to ammonia - ammoium carbonate preparation tanks SV-401/ SV-502. For startup and make up for losses in ammonia, liquor ammonia from days storage tank ST-504 is charged to solution preparation tanks SV-401/ SV-502 using pumps P- 507 and P-508. Make up ammonium carbonate is added manually to SV-401 / SV- 502. While preparing these solutions, the recovered ammonia -ammonium carbonate from storage tank ST-502 and lean ammonia solution from storage tank ST-503 are utilized. Start- up The process of the present invention is directed towards a continuous process in which the low-grade chromite ore is continuously processed in the pilot plant to produce nickel and cobalt salt. In order to reach a continuous steady state, various vessels need to be loaded with start up materials. Section 100 First of all, truck loads of nickel containing low grade chromite ore from Orissa Mining Corporation's chromite mines site at Sukinda area of Orissa, were brought to the pilot plant site and stored in the storage area provided for the purpose. The ore was treated as described in section 100 and stored in hopper H-104. Depending on the feed rate to the reduction furnace this section operated for eight to twelve hours a day. Section 200 After erection of furnace, the burners of the two combustion chambers CC-201A and B are fired one by one. The curing of refractories was done by slowly raising the temperature up-to 800°C over a total period of 110 hours. To start operation of the furnace, the dead bed of ore on hearths was filled up. Grounded ore from H-105 is fed to the furnace through SC-101. The rabble arm was kept in motion as the ore after filling the top hearth moves down to fill the lower hearths. Ore was continuously fed to the furnace. In order to achieve the desired reducing atmosphere, the air to the combustion chamber was reduced to approximately sixty percent of the total theoretical air requirement. On attainment of desired temperature (700-800°C in reduction zone), the dried ore with or without addition of light diesel oil is charged at the required rate varying between 200 to 500 kgs/hr. The reducing atmosphere is maintained in the furnace in order to complete the reduction reactions. To avoid ingress of air, the furnace is kept under positive pressure. The reduced material is discharged to screw conveyers SC-201A and SC-201B (jacketed), where it gets cooled to be filled with ammonia -ammonium carbonate solution of required composition as described in leaching section start up procedure. Section 300 and 400 Before feeding of reduced ore to section 300, various reactors and thickeners in section 300 and 400 were filled with solution containing ammonia and ammonium carbonate of required composition. The solution was prepared in preparation tanks SV-401 and SV-502. The solution was prepared in batches of 3 kiloliters by adding water, ammonium carbonate and liquor ammonia. From these tanks, the solution was charged to SV-301 and from SV-301 the solution was filled to all the reactors, thickeners and storage tanks of section 300 and 400. Section 500 In Section 500 no equipment was required to be loaded with any solution/solids prior to feeding the nickel containing leach liquor for ammonia stripping and basic nickel carbonate precipitation. The steam required to accomplish stripping of ammonia was supplied by an oil-fired boiler. The process briefly comprises of material preparation and drying, reduction-roasting, leaching with ammonia-ammonium carbonate in the presence of air or oxygen at elevated pressure , recovery of nickel as nickel salt after removing ammonia and ammonium carbonate and obtaining a residue which is suitable for coal washeries or for iron production. The following examples are given by way of illustration and therefore should not be construed to limit the scope of the present invention Examples The low grade chromite ore having about 0.5 to 0.9 % Ni (dry basis) and moisture content varying between 15 to 40% was used as the raw material in the ore drying and grinding section. The various samples collected from the output from this section had the composition range given in Table 1. These materials were used as feed to the furnace. (Table Removed) The material was crushed, dried and ground to get 85% fraction as -200 mesh B.S.S. The average moisture content after drying was ~ 1-2%. The dried ore was mixed with 0-5% fuel oil. The specific conditions and results obtained are given below: Variation of parametrs in the multiple hearth furnace was studied by feeding the dried low grade chromite ore continuously to the MHF and by carrying out the leaching of samples collected from the sampling point provided at the inlet of quench tank. These samples were leached under the conditions established in the laboratory to get maximum leaching efficiency. Example 1 Feed rate to the multiple hearth furnaces Oil in feed Time of running the experiment. Retention time in the furnace Temperature of gas in reduction zone Chamber temperature Oil feed to the combustion chamber Overall Extraction Eff. in reduction -leaching Example 2 Feed rate to the multiple hearth furnaces Oil in feed Time of running the experiment. Retention time in the furnace Temperature of gas in reduction zone Chamber temperature Oil feed to the combustion chamber Overall Extraction Eff. in reduction -leaching Example 3 Feed rate to the multiple hearth furnaces Oil in feed Time of running the experiment. Retention time in the furnace Temperature of gas in reduction zone Chamber temperature 300kg/hour 5% 48 hours 90 minutes 600-700°C ~1250-1350°C 26-30 liters/hour -60% 300kg/hour 72 hours 90 minutes 700-800°C 1350-1450°C 26- 30 liters/hour 78% 300kg/hour 2.5% 216 hours 90 minutes 700-800°C 1350-1450°C Oil feed to the combustion chamber Overall Extraction Eff. in reduction -leaching Example 4 Feed rate to the multiple hearth furnaces Oil in feed Time of running the experiment. Retention time in the furnace Temperature of gas in reduction zone Chamber temperature Oil feed to the combustion chamber Overall Extraction Eff. in reduction-leaching 29- 30 liters/hour 77.5% 300kg/hour nil 28 hours 90 minutes 700-800°C ~1350-1450°C 29-30 liters/hour 75% Examples of Continuous Reduction-Leaching Results Example-5 (Leaching using compressed air without maintaining elevated pressure) Reduction conditions Feed rate Retention time in the furnace Temperature of gas in reduction zone Oil in feed Chamber temperature Oil feed to the combustion chamber Leaching conditions: Time of continuous operation Ammonia concentration (total) C02 Retention time Flow rate in leaching reactors Compressed air Reactor 1 Reactor2 ReactorS R. :-tor4 Overall Extraction Eff. in reduction -leaching 300kg/hour, 90 minutes, 700-800°C 2.5%, ~1350-1450°C 29- 30 liters/hour 72 hours 30-40g/l 15-20g/l 4.5 hours 1.6KL/hour 15 kg/hour ~15kg/hour -15 kg/hour -15 kgs/hour -40% Example-6 (leaching using compressed air maintaining reactors) Reduction conditions Feed rate Retention time in the furnace Temperature of gas in reduction zone Oil in feed Chamber temperature Oil feed to the combustion chamber Leaching conditions: Time of continuous operation Ammonia concentration (total) CO, Retention time Flow rate in leaching reactors Compressed air Reactor 1 Reactor2 Reactor3 Reactor4 Overall Extraction Eff. in reduction -leaching 0.2 kg/cm2 in the first two 300kg/hour. 90 minutes, 700-800°C 2.5%, ~1350-1450°C 29- 30 liters/hour 48 hours 85 to 100g/l 55-65 g/1 4 hours 1.6KL/hour 20 kg/hour 20kg/hour 20 kg/hour 20kgs/hour -77% Example-7 (Leaching with compressed air maintaining 0.2 kg/cm2 in first two reactors) Reduction conditions Feed rate Retention time in the furnace Temperature of gas in reduction zone Oil in feed Chamber temperature Oil feed to the combustion chamber Leaching conditions: 450kg/hour, 90 minutes, 700-800°C 2.5%, ~1350-1450°C 29- 30 liters/hour Time of continuous operation Ammonia concentration (total) CO2 Retention time Flow rate in leaching reactors Compressed air Reactor 1 Reactor2 ReactorS Reactor4 ReactorS Reactor6 Reactor 7 Overall recovery in reduction -leaching Example 8 (leaching using oxygen gas) Reduction conditions Feed rate Retention time in the furnace Temperature of gas in reduction zone Oil in feed Chamber temperature Oil feed to the combustion chamber Leaching conditions: Time of continuous operation Ammonia concentration (total) C02 Retention time Flow rate in leaching reactors Oxygen partial pressure Overall recovery in reduction -leaching: Example 9 leaching using oxygen Reduction conditions Feed rate 288 hours 60-75g/l 45-50 g/1 -4.5 hours ~2.5KL/hour -22 kg/hour ~22kg/hour -20 kg/hour ~20kgs/hour ~10kgs/hour ~10kgs/hour ~10kgs/hour -78% 300kg/hour 90 minutes 700-SOOT 2.5% ~1350-1450°C 29- 30 liters/hour 72 hours 85-90g/l 35-40 g/l one hour -1.6KL/hour 0.7-0.8kg/cm2 -76% 500kg/hour 90 minutes 700-800°C 2.5% ~1350-1450°C 29- 30 liters/hour Retention time in the furnace Temperature of gas in reduction zone Oil in feed Chamber temperature Oil feed to the combustion chamber Leaching conditions: Time of continuous operation Ammonia concentration (total) CO2 Retention time Flow rate in leaching reactors Oxygen partial pressure Overall recovery in reduction -leaching Example 10 Ammonia stripping and recovery Initial analysis of leach solution : Conditions for stripping Tower temperature : Inlet pressure of steam : Stripping efficiency : Ni precipitation efficiency : Analysis of Nickel carbonate obtained Ni 49.5%, Co 0.54%, Fe 0.83%, Mn 0.9%, MgO 0.21%, Cr2O3, Cu 0.7% Example 11 Treatment of the leach residue (step 6) A typical leach residue containing 0.21% Ni, 46% Fe and 21.2% acid insoluble was taken for wet magnetic separation. Nine tonnes of residue was subjected to low intensity wet magnetic separation to get magnetite concentrate and reject containing gangue materials. The analysis of the magnetic material (5.6 tonnes) was iron 56%, acid insolubles 9% phosphorous 0.016%. This material can be used in coal beneficiation plant as heavy media separation or for iron making using smelting technique. The main advantages of the invention for this process are: 1. Low grade Chromite ore which is a w ^aterial can be utilized to recover strategic metals like nickel and cobalt. 2. The dried and ground material can be fed to the furnace without mixing oil. 72 hours 85-90g/l 35-40 g/1 one hour ~1.6KL/hour 0.7-0.8kg/cm2 -76% Ni 5.6g/l. NH3 80-85g/l 100-103°C 2.4-2.6Kgs/hour 98% 99% 3. The retention time for completion of nickel dissolution and iron precipitation is reduced to 0.5 to 2 hours from six hours as practiced in the existing plants when oxygen is used and to 4.5 hours when compressed air is used by maintaining an elevated pressure of- 0.2 kg/cm2. 4. Use of oxygen gas during leaching eliminates the need of elaborate ammonia recovery system and thus minimizes ammonia losses in the plant operation. 5. The iron content of the leach residue can be upgraded by wet magnetic separation. The upgraded material due to its fineness can be used for heavy media separation in coal washeries. This material is also suitable for iron production due less phosphorus content. We Claim: 1. A process for extraction of nickel from low-grade chromite ore containing 0.6 to 0.9% nickel, the said process comprises the steps of: (a) crushing, drying and grinding the chromite ore to obtain crushed chromite ore having particle size ranging between 100 to 400 mesh British Standard Seive. (b) roasting the crushed chromite ore of step (a) at a temperature in the range of 600-800°C to effect reduction, (c) cooling the roasted ore; at a temperature less than 25°C (d) mixing the cooled reduced ore of step © with a leaching solution containing ammonia and ammonium carbonate to form a slurry, passing compressed oxygen or air through the slurry at a pressure in the range of 0.2 to 1.5 Kgs.cm 2and aging the slurry for 45 minutes to 6 hours to effect leaching; (e) oxidizing the leached slurry of step(d) in presence of excess ammonia to obtain a pregnant leach solution and leach residue; (f) separating the pregnant leach solution from the leach residue by counta current decantation and washing the pulp with ammonia-ammonium carbonate solution; (g) stripping ammonia from the pregnant leach solution of step (f) to effect precipitation of dissolved nickel and cobalt in the form of their respective salts. 2. A process as claimed in claim 1, wherein the low-grade chromite ore contains 0.6 to 0.9 wt% Ni, 0.034 to 0.044 wt% Co, 43 to 53 wt % Fe, 2.42 to 2.72 wt %Cr203and 6.9 to 8.8 wt% Al203 and the rest being impurities. 3. A process as claimed in claim 1 wherein, the crushed low-grade chromite ore is fed to the multiple hearth furnace optionally premixing fuel oil. 4. A process as claimed in claim 1 wherein, the crushed low-grade chromite ore is reduced by passing CO/(CO+CO2) and H2 having a reduction potential of 0.2 to 0.6 through the multiple hearth furnace. 5. A process as claimed in claim 1 wherein in step (d), the leaching solution contains 60 to 90 g/l ammomia and 80 to 120 g/l ammomium carbonate. 6. A process as claimed in claim 1 wherein if oxygen is used in step (d), the slurry is aged for 45 minutes to 2 hours. 7. A process as claimed in claim 1 wherein if air is used in step (d), the slurry is aged for 3 hours to 6 hours. 8. A process as claimed in claim 1 wherein in step (f), the pulp is washed with ammonia-ammonium carbonate solution using counter current technique. 9. A process as claimed in claim 1 wherein in step (g), ammonia is removed from the pregnant leaching solution by passing steam through the same. 10. A process as claimed in claim 1 wherein in step (g), the dissolved nickel precipitates as basic nickel salt. 11. A process as claimed in claim 13 wherein the dissolved nickel salt precipitates as basic nickel carbonate (BCN). 12. A process as claimed in claim 1 wherein in step (g), the dissolved cobalt co-precipitates along with nickel as cobalt salt. 13. A process as claimed in claim 1 wherein the magnetic fraction is obtained is separated by wet magnetic separation technique. 14. A process for extraction of nickel substantially as herein describe with reference to examples accompanying this specification.

Full Text

A PROCESS FOR EXTRACTION OF NICKEL FROM LOW GRADE
CHROMITE ORE
Technical Field
The present invention relates to a process for the extraction of nickel from low-grade
chromite ore. Particularly, the present invention relates to a process for the extraction
of nickel and cobalt from low-grade chromite ore.
Background Art
Nickel is a strategic metal which finds use in steel, chemical, cryogenics, food
processing, and aerospace industries. The present consumption of nickel in India is
estimated to be -20,000 tons per annum (tpa), and its annual growth rate is 5-7%.
With rapid industrial growth, the demand for ferro-nickel is likely to exceed the
projected figure. Most of the demand for nickel is presently being met through
imports incurring foreign exchange worth of -Rs.1000 crores per year. Cobalt is also
a strategic metal and its demand in India is -150 tpa. In the present process cobalt is
recovered as a by-product. The only nickel deposit in India is in the Sukinda region of
Orissa. i he resources are estimated to be approximately 32 million tons in lateritic
deposits oi Sukinda region having ~1% nickel in the non-chromite and approximately
200 million tonne as low-grade chromite ore having an average of 0.7% nickel. For
any commercial exploitation of Sukinda deposit for reasonable period of time low
grade chromite ore will be the largest resource. Large stock piling of low-grade ore
(which cannot be exploited for recovery of chromite) in Sukinda region has lead to
environmental problem. It destroys natural forests around the mines and may
contribute hexavalent chromium to water stream. In the world, presently there is no
operating plant using such low-grade nickel containing materials particularly the lowgrade
chromite ore.
The major oxide ore deposits are in Indonesia, Phillipines, Cuba, Dominical Republic,
Colombia, and New Caledonia. While the Colombian ore is perhaps the richest with
more than 2.9% nickel, the poorest ores being commercially used are from Nicaro,
Cuba and Kazakstan, containing ~ 1.1% nickel. The discarded low grade chromite ore
generated at Sukinda region of Orissa, India contains in an average only -0.7%
nickel.
Reference may be made to one of the conventional methods for dissolution of nickel
from these laterites by acid pressure leaching for which a commercial plant at Moa
Bay is in operation (E.T Carlson, C.S Simons, Journal of Metals, 1960. 198(3), p 206-
213) and another plant based on pressure leaching-solvent extraction has been set
up in Australia.
The other method is by reduction-roasting followed by oxidative ammoniacal
leaching and is named as Caron's process (M.S. Caron, United State Patent 1.487,145.
March 18, 1924). A number of commercial plants including one at Nicaro. Cuba and
the other at Greenvale, Australia are in operation. Many International Conferences
have since been devoted to the advances in metallurgy of nickel and cobalt (e.g.,
International Laterite Symposium, AIME-SME Annual Meeting, New Orleans,
February 1979, International Symposium on Nickel Metallurgy held at Montreal
1986, Symposium on Metallurgy of Nickel and Cobalt, held at Arizona, Jan 25th to
28lh, 1988, Nickel and Cobalt 97-International Symposium held at Sudbury, Ontario,
Canada during Aug. 17-20 1997). The most widely commercially applicable process is
still the Caron's process (M.H. Caron, Journal of Metals, 1950, vol. 188(1), p 67-90).
In this process the nickel ore is reduced and treated with ammonia-ammonium
carbonate solution in the presence of compressed air. During leaching the reduced
nickel and cobalt form soluble amine complexes and the reduced iron comes first to
solution as ferrous amine and subsequently gets oxidized to hydrated ferric oxide. The
time required for almost complete dissolution of desired metals and precipitation of
iron in the commercial plants is about six hours. Although most of the nickel in the
world is present as oxide, due to ease of beneficiation, sulphides of nickel are the
major source of nickel production. But with depletion of good grade sulphide ore,
slowly the use of oxides for nickel extraction is increasing. Currently, roughly about
40% of the nickel is produced from oxide ore.
Drawbacks of the earlier processes
(i) All the processes for extracting nickel and cobalt known as of date use nickel
ore containing -1.1 to 1.5% Ni. The low-grade chromite ore containing 0.5 to
0.9% nickel has never been used in any process in the world following
leaching with ammonia - ammonium carbonate solution,
(ii) The results on continuous test work are not available for low-grade chromite
ore.
( i i i ) In all the existing plants oil is mixed with the dried ore prior to feeding to the
furnace for reduction, and nowhere in the world reduction step has been
carried out without mixing oil to the ore prior to reduction.
( i v ) The present plants use compressed air for oxidation and dissolution of nickel
in the leaching reactors. The retention time of about six hours is required to
complete nickel dissolution and iron precipitation. In order to reduce the
retention time, no efforts have been reported.
(v) The use of compressed air during leaching requires elaborate ammonia
recovery system to minimize ammonia losses from the vent gases.
(vi) The leach residues obtained after Ni recovery from the lateritic ore contains
primarily magnetite. These residues are being discarded. No efforts have been
reported for the utilization of these residues.
Due to lack of information on utilization of low Ni containing material such as lowgrade
chromite ore, studies have never been done to exploit this resource for the
recovery of nickel and cobalt.
Objects of the Present Invention:
The main objective of the present invention is to provide a process for the extraction
of nickel from low-grade chromite ore.
Another objective of the present invention is to enhance leaching rate with gaseous
oxygen.
Still another object of the present invention is to use compressed air at elevated
pressure in the range of 0.2 to 1.5 Kg./cm2 for reducing the retention time during
leaching step.
Yet another object of the present invention is to use gaseous oxygen at elevated
pressure in the range of 0.5 to 1.5 Kg./cm2 for reducing the retention time during
leaching step.
One more object of the present invention is to utilize the leach residue for its
magnetite content.
Summary of the Present Invention:
Accordingly, the present invention provides a process for extraction of nickel from low-grade chromite ore containing 0.6 to 0.9% nickel, the said process comprises the steps of:
(a) crushing, drying and grinding the chromite ore to obtain crushed chromite ore having particle size ranging between 100 to 400 mesh British Standard Seive.
(b) roasting the crushed chromite ore of step (a) at a temperature in the range of 600-800°C to effect reduction,
(c) cooling the roasted ore; at a temperature less than 25°C
(d) mixing the cooled reduced ore of step (C ) with a leaching solution containing ammonia and ammonium carbonate to form a slurry, passing compressed oxygen or air through the slurry at a pressure in the range of 0.2 to 1.5 Kgs.cm 2and aging the slurry for 45 minutes to 6 hours to effect leaching;
(e) oxidizing the leached slurry of step(d) in presence of excess ammonia to obtain a pregnant leach solution and leach residue;
(f) separating the pregnant leach solution from the leach residue by counter current decantation and washing the pulp with ammonia-ammonium carbonate solution;
(g) stripping ammonia from the pregnant leach solution of step (f) to effect precipitation of dissolved nickel and cobalt in the form of their respective salts.
Brief Description of the Accompanying Drawings:
In the drawings accompanying the specification,
Figurel represents the schematic block diagram of the process of extraction of nickel from
chromite over burden.
Figure 2 represents the process flow diagram for Section 100 (Crushing, Drying and
Grinding),
Figure 3 the process flow diagram for Section 200 (Reduction Roasting).

Figure 4 (a) represents the process flow diagram for Section 300 (Leaching with
Oxygen gas).
Figure 4 (b) represents the process flow diagram for Section 300 (First Stage
Leaching with Air).
Figure 4 (c) represents the process flow diagram for Section 300 (Second Stage
Leaching with Air).
Figure 5 represents the process flow diagram for Section 400 (counter current
decantation).
Figure 6 represents the process flow diagram for Section 500 (BNC Precipitation,
Ammonia removal and recovery).
Detailed Description of the Present Invention:
The present invention provides a process for extraction of nickel from low-grade
chromite ore containing 0.6 to 0.9% nickel, the said process comprises the steps of:
(a) crushing, drying and grinding the chromite ore to obtain crushed chromite ore
having particle size ranging between 100 to 400 mesh B.S.S;
(b) roasting the crushed chromite ore of step (a) to effect reduction;
(c) cooling the roasted ore;
(d) mixing the cooled reduced ore of step (c) with a leaching solution containing
ammonia and ammonium carbonate to form a slurry, passing compressed
oxygen or air through the slurry and aging the slurry for 45 minutes to 6 hours
to effect leaching;
(v oxidizing the leached slurry of ;,ii:p (d) in presence of excess ammonia to
obtain a pregnant leach solution and leach residue;
(t) separating the pregnant leach solution from the leach residue and washing the
pulp with ammonia-ammonium carbonate solution, and
(g) stripping ammonia from the pregnant leach solution of step (f) to effect
precipitation of dissolved nickel and cobalt in the form of their respective
salts.
In an embodiment of the present invention the low-grade chromite ore contains 0.6 to
0.9 wt. % Ni, 0.034 to 0.044 wt. % Co. 43 to 53 wt. % Fe, 2.42 to 2.72 wt. % Cr2O3
and 6.9 to 8.8 wt. % Al2O3 and the rest being impurities.
In another embodiment of the present invention, wherein in step (a), 85% of the
crushed chromite ore have particle size of 200 mesh B.S.S.
In yet another embodiment of the present invention, wherein in step (b), crushed lowgrade
chromite ore is roasted in a multiple hearth furnace at a gas temperature in the
range of 600 to 800°C to effect reduction.
In still another embodiment of the present invention, the crushed low-grade chromite
ore is fed to the multiple hearth furnace with or without premixing fuel oil.
In one more embodiment of the present invention, the crushed low-grade chromite ore
is reduced by passing CO / (CO+ CCO2) and H2 having a reduction potential of 0.2 to
0.6 through the multiple hearth furnace.
In one another embodiment of the present invention, wherein in step (c), the roasted
chromite ore is cooled to a temperature less than 250°C.
In further embodiment of the present invention, wherein in step (d), the leaching
solution contains 60 to 90 g/1 ammonia and 80 to 120 g/1 ammonium carbonate.
In an embodiment of the present invention, wherein in step (d), the pressure of the
compressed oxygen or air is in the range of 0.2 to 1.5 Kgs/cm2.
In another embodiment of the present invention, if oxygen is used in step (d), the
slurry is aged for 45 minutes to 2 hours.
In yet another embodiment of the present invention, if air is used in step (d), the slurry
is aged for 3 hours to 6 hours.
In still another embodiment of the present invention, wherein in step (f), the pulp is
washed with ammonia-ammonium carbonate solution using counter current
decantation technique.
In one more embodiment of the present invention, wherein in step (g), ammonia is
removed from the pregnant leaching solution by passing steam through the same.
in one another embodiment of the present invention, the ammonia removed from the
pregnant leaching solution is recovered and re-used.
In a further embodiment of the present invention, wherein in step (g), the dissolved
nickel precipitates as basic nickel salt.
In an embodiment of the present invention, the dissolved nickel salt precipitates as
basic nickel carbonate (BCN).
In another embodiment of the present invention, wherein in step (g), the dissolved
cobalt co-precipitates along with nickel as cobalt salt.
In yet another embodiment of the present invention, the leach residue obtained in step
(0, is used for extracting magnetic fraction.
In still another embodiment of the present invention, the magnetic fraction is obtained
is separated by wet magnetic separation technique.
In one more another embodiment of the present invention, the magnetic fraction thus
obtained is used for production of low phosphorous iron production.
The novelty of the present invention lies in the following factors:
1) Use of Low Grade Chromite Ore for extraction of nickel, cobalt and iron.
2) Reduction roasting without premix of additive such as oil.
3) Use of oxygen/air during leaching at an elevated pressure.
4) Generation of magnetite residue suitable for coal washeries
5) Generation of low phosphorous containing magnetite for low phosphorous
iron production
The schematic block diagram of the process is shown in Fig 1. The main steps of the
process are divided into following steps.
1. Ore drying and grinding.
2. Reduction roasting
3. Ammonical leaching
4. Counter current washing and decantation
5. Basic nickel carbonate precipitation , ammonia stripping and recovery
6. Testing for residue utilization
A pilot plant has been set up jointly by Council of Scientific and Industrial Research,
(CSIR) and Hindustan Zinc Limited (HZL) at the premises of Regional Research
Laboratory, Bhubaneswar 751013. The pilot plant used for carrying out the work for
the production of nickel salt from low-grade chromite ore is divided into the
following five sections. These are:
Section 100: Ore Preparation
Section 200: Reduction Roasting
Section 300: Leaching
Section 400: Counter Current Decantation
Section 500: Precipitation of nickel salt
The other utilities provided are:
1. Producer Gas Generator
2. Instrument Air Compressor
3. Reciprocating Air Compressor
4. Cooling Tower
5. Boiler
6. Fire Extinguisher
The operating principles for each section are described below:
Ore Preparation (Section 100, Step-1)
The flow diagram for Section 100 (ore preparation) is shown in Fig 2. The raw
material is stored in the storage area SY-101, which is an area at the ground level with
suitable curbing on all four sides to avoid spread of material. SY-101 is housed inside
a covered shed to avoid rain or water ingress. The raw material is loaded manually
into container CN-101, mounted on a trolley TR-101. The trolley is placed below the
overhead electric hoist EH-101. The electric hoist lifts the container CN-101 and
unloads the raw material into a grizzley GR-101. The material with size -50 mm
passes through GR-101 and is fed into the hopper H-101. The oversize material is
manually broken and fed again to grizzley GR-101.
The material collected in hopper H-101 is fed into a jaw-cum-roll crusher JC-101
through a vibratory feeder VF-101. JC-101 reduces the size of the raw material to -6
mm. The oversize (+ 6 mm) from jaw crusher JC-101 is fed to a roll crusher RC-101.
The sized output from the combined unit of Jaw-cum-Roll crusher JC-101 and Roll
crusher RC-101 is discharged on a belt conveyor BC-101 which feeds to a bucket
elevator BE-101. The bucket elevator delivers the material to an overhead storage bin
H-102, which discharges the material to a screw feeder SF-101. The discharge of SF-
101 is fed to a drum drier D-101. The material is dried co-currently in drum dryer D-
101 by passing products of combustion of o: the dryer. ST-102 provides oil to the burner - ed to the combustion chamber. This
tank receives oil from the main oil storage tank. Air to the combustion chamber is
provided by fan/blower B-101. The output from the dryer is dried material with 1-3%
tree moisture and 10-11% bound moisture. The material from D-101 is collected in a
hopper H-103.
The dried material from hopper H-103 is fed into a ball mill BM-101 at the specified
rate through a rotary valve RV-101. The rotary valve also prevents ingress of air to
the ball mill when material is being fed into it. A blower B-102 supplies air to the ball
mill which of air swept type. In the ball mill BM-101, the dried material is reduced in
size to 85% -200 mesh B.S.S.
The finer part of discharge from drum dryer D-101 goes directly to day storage bin H-
104 by bucket elevator BE-102 through a cyclone separator C-101 and BF-101. The
discharge from ball mill BM-101 passes through a cyclone separator C-102, rotary
valve RV-102, and collected in the day storage bin H-104 by bucket elevator BE-102.
The gases/air containing solid particles which comes out of the dryer & ball mill
passes through the cyclone separators C-101 and C-102, bag filters BF-101 and BF-
102 and gas/air is discharged through blowers B-104 and B-103 to the atmosphere
through stacks STA-101 and STA-102 respectively.
The storage bin H-104 has a capacity to store one day's requirement (-10 tons) of
dried raw material. The material from H-104 is discharged into a trolley container
CN-102A&B which is placed on a trolley TR-102A/B. CN-102A/B has a capacity of
-0.5 tons. Oil (as and when required) is manually mixed with the ore and the trolley is
pushed on rails below a hoist EH-102 which lifts the container and discharges the
material into the hopper H-105 on top of MHF-20L From the hopper the material is
delivered to screw conveyor SC-101 at the required rate. The rate of feeding to MHF-
201 can be varied by adjusting the valve provided in the discharge of hopper H-105.
A rotary valve RV-103 is provided at the outlet of screw conveyer SC-101 for feeding
of COB at a constant rate to MHF. This also avoids escape of flue gases from the
MHF into the atmosphere.
The oil storage tank ST-101 receives the oil from main oil storage tank and supplies
oil to the combustion chamber of the MHF-201.
Reduction Roasting (Section 200, Step-2)
The flow diagram for reduction roasting is given in Fig. 3.
The pre-processed raw material from section 100 (85% - 200 Mesh B.S.S. containing
i free moisture) is fed into the Maniple Hearth Furnace MHF-201 from the
hopper H-105. MHF-201 has a capacity to process 500 kg of raw material per hour.
The MHF-201 is a 17-hearth furnace (0-16), with four rabble arms per hearth. The
raw material in the MHF is heated by means of gases coming from the combustion
chambers CC-201 A and B. The products of combustion chambers are fed into the
MHF-201 through suitable ducting to deliver the gases at hearth numbers 15.13 and
1 1 . The two combustion chambers are located diametrically opposite to each other.
The rabble arms are rotated by means of a central shaft which is air cooled. The
cooling air to the shaft is supplied by blower B-202. The hot air after cooling the
central shaft is used in the pre heating of hearths and is partly let out through the stack
STA-201.
The combustion chambers CC-201 A/B are supplied with Light Diesel Oil (LDO)
from the oil storage tank ST-101 (ref Fig-2). The combustion air required is supplied
by blower B-201. The burners of the combustion chambers are dual fuel fired type,
with a provision to burn producer gas also. The oil supply to CC-201 A/B is measured
by means of flow transmitters.
The MHF-201 can be divided into three zones. The first zone comprising of hearths 0
to 3 is the ore-preheating zone. Hearths 4 to 14 comprise of the reduction roasting
zone and hearths 15 and 16 comprise of the soaking zone. The total residence time in
the MHF can be controlled by varying the shaft speed. The flue gases composed of
CO, COo and H2 from CC-201 A/B come in contact with the feed material through hot
gas ducts in the reduction roasting zone and the material gets reduced. The reducing
atmosphere is maintained in the MHF-201 by additionally injecting LDO/fresh
producer gas through nozzles provided in this zone. The rate of addition of producer
gas can be measured by flow transmitter. The desired CO-CO2 ratio is maintained.
The unreacted CO and Hi in the reducing gas are burnt in the preheating zone by
injecting hot air which is provided through the shaft cooling blower B-202. The MHF-
201 is provided with nozzles for sampling both gas and solid at various locations. The
temperature profile of the MHF-201 is measured and recorded by a multi-point
temperature scanner.
The hot flue gases at about 425°C are let out from MHF-201 from the top. Any solid
carry over in the flue gases is recovered in the dust recovery system comprising of a
multi cyclone separator C-201. The solids are re-introduced into MHF-201 through
motorized rotary valve RV-201. The gases from C-201 are then passed through
ventury scrubber VS-201 and demister S-201 before being discharged to the
atmosphere by blower B-203. Water is circulated using pump P-201 in the ventury
scrubber VS-201 and demister S-201 at a constant rate to cool and clean the exhaust
gases.
The reduced low-grade chromite ore from MHF-201 is discharged into a jacketed
screw conveyer SC-201A. Cold water is circulated in the jacket for cooling the
reduced low-grade chromite ore. The cooled material is further conveyed through
another screw conveyer SC-201B into the quench tank SV-301. The temperature of
the cooled material is less than 250°C.
Leaching (Section 300, Step-3)
In the leaching section there are two options namely
(i) Use of oxygen during leaching at elevated pressure
(ii) Use of compressed air at elevated pressure
Leaching using gaseous oxygen at elevated pressure
The process flow diagram for leaching with oxygen gas is shown in Fig 4 (a).
The reduced ore after cooling in SC-201A&B is discharged continuously in a sealed
atmosphere into the quench tank SV-301. The quench tank receives solution
containing ammonia, ammonium carbonate and nickel through two streams
separately from ST-301 by using pump P-304 (after cooling it to about 38°C in a
double pipe heat exchanger E-301) and from storage tank ST-401 by using pump P-
401 (refer Fig.5). Make up ammonia-ammonium carbonate solution may be fed to the
quench tank SV-301 from the solution preparation tanks SV-401/SV-502 using pumps
P-507 and P-508 (ref. Fig.6) to obtain the required concentration of leachant. The
coolant in E-301 is cooling water. In the quench tank SV-301 the hot solids are added
to the quench liquor to form required slurry concentration with an outlet temperature
of around 40°C. The quenched slurry is pumped to the first reactor, R-301A by pump
P-301. The slurry overflows to reactor R-301B by gravity. Oxygen is supplied to both •
the leaching reactors by maintaining the desired gauge pressure. Oxygen supply to the
reactors is controlled by pressure control valves which are maintained at the desired
pressure. The slurry, after leaching is transferred due to the pressure in the reactor R-
30IB to the leach slurry thickener TH-301A. The oxidizing ammonia leach is done in
the presence of excess ammonia to prevent precipitation of nickel and cobalt as
hydroxides, resulting in a pH of about 10-11 in the pregnant leach solution. The
thickened underflow from TH-301A is pumped to the CCD section by pump P-302 to
TH-401 A. The overflow from TH-301A flows by gravity to ST-301.
The flow rates of quench slurry, leached slurry, and pregnant leach solution to the
section for precipitation of nickel salt and to quench tanks are controlled through
valves and the flows are indicated by transmitters/ indicators. As stated above part of
the leach solution from the storage tank ST-301 is pumped to SV-301 through the
cooler E-301. The other part of the leach liquor goes to filter press FI-301A &B by
pump P-303. The filtrate is collected in storage tank ST-304 from where it is fed to
the tower T-501 by pump P-305.
Leaching Using Compressed Air at elevated pressure
The procedure for leaching with compressed air is similar except that the number of
reactors and thickeners are more for providing longer retention time. The flow
diagrams for leaching using compressed air are shown in Fig 4 (b) and 4 (c).
In case of air leaching, the leaching operation is carried out in two stages, the first
stage consisting of four reactors R-301A to R-301D and the second stage consisting
of three reactors R-301E to R-301G. The flow of slurry between the reactors within
each stage is by gravity. The last reactor of the first stage R-301D discharges slurry
by gravity into the first thickener TH-301 A, from where the underflow is pumped into
the first reactor of the second stage R-301E. The clear solution overflowing from TH-
301 A is collected in the storage tank ST-301. A part of this solution is pumped to the
quench tank SV-301 through a cooler E-301. Another portion of the leach solution
is pumped to the BNC precipitation section (Section 500) through a batch filters FI-
301A & B for further processing. The filter is used to remove any residual solids from
the leach solution.
The thickened underflow from TH-301 A is pumped by P-302 to the first reactor R-
301E of the second stage leaching. From R-301E, the slurry flows to reactors R-301F
and R-301G and finally to the thickener TH-301B by gravity. The clear solution from
TH-301B is collected in storage tank ST-302 and a part of it is pumped to the quench
tank and another part is recycled back to R-301E, by pump P-307. The underflow
from TH-301B is pumped to the CCD section (sec. 400) by pump P-306. The vents
are connected to a ventury scrubbing system.
Counter Current Decantation (Section 400, Step- 4)
In this section, separation of pregnant leach solution from leach residue and washing
of the pulp with ammonia-ammonium carbo -olution is carried out using a series
ol thicKeners TH-401A, B, C, D and E as >. in Fig.5. The washing of the leach
residue is done counter currently. The underflow slurry is pumped from one thickener
to another by pumps P-402 to P-405. Pump P-406 is used to discard the washed slurry
from TH-405 to the tailings pond. The flow of slurry and flow of clear overflow from
one thickener to another is as shown in the Fig.5.
Precipitation of nickel salt and Ammonia Recovery (Section 500, Step- 5)
The flow diagram for this section is given in Fig. 6. The leach solution containing
dissolved nickel from the leach solution storage tank ST-304 is pumped by P-305 to
the top of a stripping column, T-501. Steam is admitted at the desired pressure from
the bottom of the column for stripping of ammonia and carbon dioxide from the
pregnant leach solution. The descending solution is gradually depleted of ammonia
until nickel precipitates as basic nickel carbonate (BNC). The dissolved cobalt also
co-precipitates in this step.
The mixed nickel and cobalt salt is precipitated in the column is discharged from the
bottom at cooled with water circulation before pumping it to batch filter FI-501A/B. The cake
from the filter is recovered, weighed and analyzed for nickel and other metals. The
filtrate is collected in the storage tank ST-505 and pumped to the thickener TH-401E
for washing of the final tailings coming from thickener TH-401D of section 400.
The vapors from the tower T-501 are condensed in the heat exchanger E-501. The
gases are cooled by cooling water circulation in it. The condensed liquid containing
ammonia is collected in the condensate tank ST-502. The uncondensed vapors from
E-501 are sent to an absorption tower T-502 for the recovery of residual ammonia.
The gases are scrubbed with fresh water fed from the top of the tower T-502 and or by
re-circulation of lean ammonia solution from ST-503. The vapors free of ammonia are
discharged to the atmosphere. The ammonia solution from ST-502 is cooled in a
water cooled double piped heat exchanger E-502 and is pumped to ammonia -
ammoium carbonate preparation tanks SV-401/ SV-502.
For startup and make up for losses in ammonia, liquor ammonia from days storage
tank ST-504 is charged to solution preparation tanks SV-401/ SV-502 using pumps P-
507 and P-508. Make up ammonium carbonate is added manually to SV-401 / SV-
502. While preparing these solutions, the recovered ammonia -ammonium carbonate
from storage tank ST-502 and lean ammonia solution from storage tank ST-503 are
utilized.
Start- up
The process of the present invention is directed towards a continuous process in
which the low-grade chromite ore is continuously processed in the pilot plant to
produce nickel and cobalt salt. In order to reach a continuous steady state, various
vessels need to be loaded with start up materials.
Section 100
First of all, truck loads of nickel containing low grade chromite ore from Orissa
Mining Corporation's chromite mines site at Sukinda area of Orissa, were brought to
the pilot plant site and stored in the storage area provided for the purpose. The ore
was treated as described in section 100 and stored in hopper H-104. Depending on the
feed rate to the reduction furnace this section operated for eight to twelve hours a day.
Section 200
After erection of furnace, the burners of the two combustion chambers CC-201A and
B are fired one by one. The curing of refractories was done by slowly raising the
temperature up-to 800°C over a total period of 110 hours. To start operation of the
furnace, the dead bed of ore on hearths was filled up. Grounded ore from H-105 is fed
to the furnace through SC-101. The rabble arm was kept in motion as the ore after
filling the top hearth moves down to fill the lower hearths. Ore was continuously fed
to the furnace. In order to achieve the desired reducing atmosphere, the air to the
combustion chamber was reduced to approximately sixty percent of the total
theoretical air requirement. On attainment of desired temperature (700-800°C in
reduction zone), the dried ore with or without addition of light diesel oil is charged at
the required rate varying between 200 to 500 kgs/hr. The reducing atmosphere is
maintained in the furnace in order to complete the reduction reactions. To avoid
ingress of air, the furnace is kept under positive pressure. The reduced material is
discharged to screw conveyers SC-201A and SC-201B (jacketed), where it gets
cooled to be filled with ammonia -ammonium carbonate solution of required composition as
described in leaching section start up procedure.
Section 300 and 400
Before feeding of reduced ore to section 300, various reactors and thickeners in
section 300 and 400 were filled with solution containing ammonia and ammonium
carbonate of required composition. The solution was prepared in preparation tanks
SV-401 and SV-502. The solution was prepared in batches of 3 kiloliters by adding
water, ammonium carbonate and liquor ammonia. From these tanks, the solution was
charged to SV-301 and from SV-301 the solution was filled to all the reactors,
thickeners and storage tanks of section 300 and 400.
Section 500
In Section 500 no equipment was required to be loaded with any solution/solids prior
to feeding the nickel containing leach liquor for ammonia stripping and basic nickel
carbonate precipitation. The steam required to accomplish stripping of ammonia was
supplied by an oil-fired boiler.
The process briefly comprises of material preparation and drying, reduction-roasting,
leaching with ammonia-ammonium carbonate in the presence of air or oxygen at
elevated pressure , recovery of nickel as nickel salt after removing ammonia and
ammonium carbonate and obtaining a residue which is suitable for coal washeries or
for iron production.
The following examples are given by way of illustration and therefore should not be
construed to limit the scope of the present invention
Examples
The low grade chromite ore having about 0.5 to 0.9 % Ni (dry basis) and moisture
content varying between 15 to 40% was used as the raw material in the ore drying and
grinding section. The various samples collected from the output from this section had
the composition range given in Table 1. These materials were used as feed to the
furnace.
(Table Removed)
The material was crushed, dried and ground to get 85% fraction as -200 mesh B.S.S.
The average moisture content after drying was ~ 1-2%.
The dried ore was mixed with 0-5% fuel oil. The specific conditions and results
obtained are given below:
Variation of parametrs in the multiple hearth furnace was studied by feeding the dried
low grade chromite ore continuously to the MHF and by carrying out the leaching of
samples collected from the sampling point provided at the inlet of quench tank. These
samples were leached under the conditions established in the laboratory to get
maximum leaching efficiency.
Example 1
Feed rate to the multiple hearth furnaces
Oil in feed
Time of running the experiment.
Retention time in the furnace
Temperature of gas in reduction zone
Chamber temperature
Oil feed to the combustion chamber
Overall Extraction Eff. in reduction -leaching
Example 2
Feed rate to the multiple hearth furnaces
Oil in feed
Time of running the experiment.
Retention time in the furnace
Temperature of gas in reduction zone
Chamber temperature
Oil feed to the combustion chamber
Overall Extraction Eff. in reduction -leaching
Example 3
Feed rate to the multiple hearth furnaces
Oil in feed
Time of running the experiment.
Retention time in the furnace
Temperature of gas in reduction zone
Chamber temperature
300kg/hour
5%
48 hours
90 minutes
600-700°C
~1250-1350°C
26-30 liters/hour
-60%
300kg/hour
72 hours
90 minutes
700-800°C
1350-1450°C
26- 30 liters/hour
78%
300kg/hour
2.5%
216 hours
90 minutes
700-800°C
1350-1450°C
Oil feed to the combustion chamber
Overall Extraction Eff. in reduction -leaching
Example 4
Feed rate to the multiple hearth furnaces
Oil in feed
Time of running the experiment.
Retention time in the furnace
Temperature of gas in reduction zone
Chamber temperature
Oil feed to the combustion chamber
Overall Extraction Eff. in reduction-leaching
29- 30 liters/hour
77.5%
300kg/hour
nil
28 hours
90 minutes
700-800°C
~1350-1450°C
29-30 liters/hour
75%
Examples of Continuous Reduction-Leaching Results
Example-5 (Leaching using compressed air without maintaining elevated pressure)
Reduction conditions
Feed rate
Retention time in the furnace
Temperature of gas in reduction zone
Oil in feed
Chamber temperature
Oil feed to the combustion chamber
Leaching conditions:
Time of continuous operation
Ammonia concentration (total)
C02
Retention time
Flow rate in leaching reactors
Compressed air
Reactor 1
Reactor2
ReactorS
R. :-tor4
Overall Extraction Eff. in reduction -leaching
300kg/hour,
90 minutes,
700-800°C
2.5%,
~1350-1450°C
29- 30 liters/hour
72 hours
30-40g/l
15-20g/l
4.5 hours
1.6KL/hour
15 kg/hour
~15kg/hour
-15 kg/hour
-15 kgs/hour
-40%
Example-6 (leaching using compressed air maintaining
reactors)
Reduction conditions
Feed rate
Retention time in the furnace
Temperature of gas in reduction zone
Oil in feed
Chamber temperature
Oil feed to the combustion chamber
Leaching conditions:
Time of continuous operation
Ammonia concentration (total)
CO,
Retention time
Flow rate in leaching reactors
Compressed air
Reactor 1
Reactor2
Reactor3
Reactor4
Overall Extraction Eff. in reduction -leaching
0.2 kg/cm2 in the first two
300kg/hour.
90 minutes,
700-800°C
2.5%,
~1350-1450°C
29- 30 liters/hour
48 hours
85 to 100g/l
55-65 g/1
4 hours
1.6KL/hour
20 kg/hour
20kg/hour
20 kg/hour
20kgs/hour
-77%
Example-7 (Leaching with compressed air maintaining 0.2 kg/cm2 in first two
reactors)
Reduction conditions
Feed rate
Retention time in the furnace
Temperature of gas in reduction zone
Oil in feed
Chamber temperature
Oil feed to the combustion chamber
Leaching conditions:
450kg/hour,
90 minutes,
700-800°C
2.5%,
~1350-1450°C
29- 30 liters/hour
Time of continuous operation
Ammonia concentration (total)
CO2
Retention time
Flow rate in leaching reactors
Compressed air
Reactor 1
Reactor2
ReactorS
Reactor4
ReactorS
Reactor6
Reactor 7
Overall recovery in reduction -leaching
Example 8 (leaching using oxygen gas)
Reduction conditions
Feed rate
Retention time in the furnace
Temperature of gas in reduction zone
Oil in feed
Chamber temperature
Oil feed to the combustion chamber
Leaching conditions:
Time of continuous operation
Ammonia concentration (total)
C02
Retention time
Flow rate in leaching reactors
Oxygen partial pressure
Overall recovery in reduction -leaching:
Example 9 leaching using oxygen
Reduction conditions
Feed rate
288 hours
60-75g/l
45-50 g/1
-4.5 hours
~2.5KL/hour
-22 kg/hour
~22kg/hour
-20 kg/hour
~20kgs/hour
~10kgs/hour
~10kgs/hour
~10kgs/hour
-78%
300kg/hour
90 minutes
700-SOOT
2.5%
~1350-1450°C
29- 30 liters/hour
72 hours
85-90g/l
35-40 g/l
one hour
-1.6KL/hour
0.7-0.8kg/cm2
-76%
500kg/hour
90 minutes
700-800°C
2.5%
~1350-1450°C
29- 30 liters/hour
Retention time in the furnace
Temperature of gas in reduction zone
Oil in feed
Chamber temperature
Oil feed to the combustion chamber
Leaching conditions:
Time of continuous operation
Ammonia concentration (total)
CO2
Retention time
Flow rate in leaching reactors
Oxygen partial pressure
Overall recovery in reduction -leaching
Example 10 Ammonia stripping and recovery
Initial analysis of leach solution :
Conditions for stripping
Tower temperature :
Inlet pressure of steam :
Stripping efficiency :
Ni precipitation efficiency :
Analysis of Nickel carbonate obtained
Ni 49.5%, Co 0.54%, Fe 0.83%, Mn 0.9%, MgO 0.21%, Cr2O3, Cu 0.7%
Example 11 Treatment of the leach residue (step 6)
A typical leach residue containing 0.21% Ni, 46% Fe and 21.2% acid insoluble was
taken for wet magnetic separation. Nine tonnes of residue was subjected to low
intensity wet magnetic separation to get magnetite concentrate and reject containing
gangue materials. The analysis of the magnetic material (5.6 tonnes) was iron 56%,
acid insolubles 9% phosphorous 0.016%. This material can be used in coal
beneficiation plant as heavy media separation or for iron making using smelting
technique.
The main advantages of the invention for this process are:
1. Low grade Chromite ore which is a w ^aterial can be utilized to recover
strategic metals like nickel and cobalt.
2. The dried and ground material can be fed to the furnace without mixing oil.
72 hours
85-90g/l
35-40 g/1
one hour
~1.6KL/hour
0.7-0.8kg/cm2
-76%
Ni 5.6g/l. NH3 80-85g/l
100-103°C
2.4-2.6Kgs/hour
98%
99%
3. The retention time for completion of nickel dissolution and iron precipitation is
reduced to 0.5 to 2 hours from six hours as practiced in the existing plants when
oxygen is used and to 4.5 hours when compressed air is used by maintaining an
elevated pressure of- 0.2 kg/cm2.
4. Use of oxygen gas during leaching eliminates the need of elaborate ammonia
recovery system and thus minimizes ammonia losses in the plant operation.
5. The iron content of the leach residue can be upgraded by wet magnetic separation.
The upgraded material due to its fineness can be used for heavy media separation
in coal washeries. This material is also suitable for iron production due less
phosphorus content.

We Claim:
1. A process for extraction of nickel from low-grade chromite ore containing 0.6 to 0.9%
nickel, the said process comprises the steps of:
(a) crushing, drying and grinding the chromite ore to obtain crushed chromite ore having particle size ranging between 100 to 400 mesh British Standard Seive.
(b) roasting the crushed chromite ore of step (a) at a temperature in the range of 600-800°C to effect reduction,
(c) cooling the roasted ore; at a temperature less than 25°C
(d) mixing the cooled reduced ore of step © with a leaching solution containing ammonia and ammonium carbonate to form a slurry, passing compressed oxygen or air through the slurry at a pressure in the range of 0.2 to 1.5 Kgs.cm 2and aging the slurry for 45 minutes to 6 hours to effect leaching;
(e) oxidizing the leached slurry of step(d) in presence of excess ammonia to obtain a pregnant leach solution and leach residue;
(f) separating the pregnant leach solution from the leach residue by counta current decantation and washing the pulp with ammonia-ammonium carbonate solution;
(g) stripping ammonia from the pregnant leach solution of step (f) to effect precipitation of dissolved nickel and cobalt in the form of their respective salts.

2. A process as claimed in claim 1, wherein the low-grade chromite ore contains 0.6 to 0.9 wt% Ni, 0.034 to 0.044 wt% Co, 43 to 53 wt % Fe, 2.42 to 2.72 wt %Cr203and 6.9 to 8.8 wt% Al203 and the rest being impurities.
3. A process as claimed in claim 1 wherein, the crushed low-grade chromite ore is fed to the multiple hearth furnace optionally premixing fuel oil.

4. A process as claimed in claim 1 wherein, the crushed low-grade chromite ore is reduced by passing CO/(CO+CO2) and H2 having a reduction potential of 0.2 to 0.6 through the multiple hearth furnace.
5. A process as claimed in claim 1 wherein in step (d), the leaching solution contains 60 to 90 g/l ammomia and 80 to 120 g/l ammomium carbonate.
6. A process as claimed in claim 1 wherein if oxygen is used in step (d), the slurry is aged for 45 minutes to 2 hours.
7. A process as claimed in claim 1 wherein if air is used in step (d), the slurry is aged for 3 hours to 6 hours.
8. A process as claimed in claim 1 wherein in step (f), the pulp is washed with ammonia-ammonium carbonate solution using counter current technique.
9. A process as claimed in claim 1 wherein in step (g), ammonia is removed from the pregnant leaching solution by passing steam through the same.
10. A process as claimed in claim 1 wherein in step (g), the dissolved nickel precipitates as basic nickel salt.
11. A process as claimed in claim 13 wherein the dissolved nickel salt precipitates as basic nickel carbonate (BCN).
12. A process as claimed in claim 1 wherein in step (g), the dissolved cobalt co-precipitates along with nickel as cobalt salt.
13. A process as claimed in claim 1 wherein the magnetic fraction is obtained is separated by wet magnetic separation technique.
14. A process for extraction of nickel substantially as herein describe with reference to examples accompanying this specification.

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Patent Number

234452

Indian Patent Application Number

483/DEL/2003

PG Journal Number

25/2009

Publication Date

19-Jun-2009

Grant Date

28-May-2009

Date of Filing

27-Mar-2003

Name of Patentee

COUNCIL OF SCIENTIFIC AND INDUSTRIAL RESEARCH

Applicant Address

RAFI MARG, NEW DELHI-110 001, INDIA

Inventors:

#	Inventor's Name	Inventor's Address
1	KODALI HIRNYA VARNA PRASAD	RAFI MARG, NEW DELHI-110 001, INDIA
2	RAJENDRA KUMAR SINGHVI	RAFI MARG, NEW DELHI-110 001, INDIA
3	VAKIL SINGH	RAFI MARG, NEW DELHI-110 001, INDIA
4	BAIJ NATH MITTAL	RAFI MARG, NEW DELHI-110 001, INDIA
5	BHUBAN LAL AGARWAL	RAFI MARG, NEW DELHI-110 001, INDIA
6	PARTHA SARATHI DATTA	RAFI MARG, NEW DELHI-110 001, INDIA
7	BHAGYADHAR BHOI	RAFI MARG, NEW DELHI-110 001, INDIA
8	MALAY KUMAR GHOSH	RAFI MARG, NEW DELHI-110 001, INDIA
9	KALI SANJAY	RAFI MARG, NEW DELHI-110 001, INDIA
10	SUBIR DAS	RAFI MARG, NEW DELHI-110 001, INDIA
11	TONDEPU SUBAIAH	RAFI MARG, NEW DELHI-110 001, INDIA
12	KARNAM SRINIVAS RAO	RAFI MARG, NEW DELHI-110 001, INDIA
13	INDRA NARAYAN BHATTACHARYA	RAFI MARG, NEW DELHI-110 001, INDIA
14	RAMCHANDRA NAGESH PARLIKAR	RAFI MARG, NEW DELHI-110 001, INDIA
15	GAJULA VENKATA YUGANDHAR	RAFI MARG, NEW DELHI-110 001, INDIA
16	UGLE ASHUTOSH	RAFI MARG, NEW DELHI-110 001, INDIA
17	HARI SIMHA	RAFI MARG, NEW DELHI-110 001, INDIA
18	KATARAM RAJESWAR RAO	RAFI MARG, NEW DELHI-110 001, INDIA
19	RADHANATH PRASAD DAS	RAFI MARG, NEW DELHI-110 001
20	ANIL KANTA TRIPATHY	RAFI MARG, NEW DELHI-110 001, INDIA
21	SHASHI ANAND	RAFI MARG, NEW DELHI-110 001, INDIA
22	SUDIPTA DAS	RAFI MARG, NEW DELHI-110 001, INDIA
23	SNEHASIS BEHERA	RAFI MARG, NEW DELHI-110 001, INDIA
24	B V RAMAN MURTY	RAFI MARG, NEW DELHI-110 001, INDIA

PCT International Classification Number

C22B 023/00

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA