The present invention relates to a process which comprises the following stages: (a) beneficiation or preparation of ores containing nickel and/or cobalt and other base metals; (b) ore leaching: can be performed in various ways and combinations of these; (c) resin in pulp: the leach product is subjected to further processing with resin in counter-current contact mode, which eliminates the solid-liquid separation; (d) solvent extraction: the eluate obtained after elution of the resin is subjected to one or more solvent extraction stages for nickel separation from cobalt, and if necessary, one or more stages for purification of the nickel-bearing raffinate; (e) nickel electrowinning: either the raffinate from stage (d) or the nickel- bearing solution obtained from the previous stage is used as feed to the electrowinning stage for obtaining the end product in the form of cathode nickel; and (f) the solvent reextraction solution, which contains cobalt along with some impurities, shall be fed to a precipitation unit for cobalt recovery.
C22B 3/00 - Extraction of metal compounds from ores or concentrates by wet processes
B01J 39/00 - Cation exchange; Use of material as cation exchangers; Treatment of material for improving the cation exchange properties
C25C 1/08 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese of nickel or cobalt
2.
PROCESS FOR RECOVERY OF NICKEL AND COBALT FROM AN ION-EXCHANGE RESIN ELUATE AND PRODUCT
The present invention relates to a process for obtaining nickel, cobalt, and other metals from ores containing them, as well as from the product obtained at any of its stages, as follows: (a) preparation or pre-treatment of the ore for its enrichment by means of silica rejection; (b) acid leaching of the pre-treated ore; (c) treatment of the effluent solution from the leaching stage using ion-exchange resin applied to the pulp; (d) elution or desorption of the ion-exchange resin using regenerated hydrochloric acid from the pyrohydrolysis stage (e) removal of copper and other impurities by precipitation, using either a sulfide or hydrosulfuric acid; (f) the solution still containing nickel and cobalt is subjected to a solvent extraction process; (g) stripping, using regenerated hydrochloric acid from the pyrohydrolysis stage (h) precipitation of cobalt in the form of either carbonate or any other intermediate product, such as sulfate, oxide, or hydroxide (i) Pyrohydrolysis of the nickel-containing solution, thus obtaining nickel in the form of oxide, and hydrochloric acid.
The process, according to the invention, comprises the following stages: (a) processing (1) of the laterite ore (O) by crushing, scrubbing, attrition, separation, and high-intensity magnetic separation; (b) Leaching (2) of the non-magnetic fraction (CN) obtained form the previous stage (a); (c) optionally, neutralization (3) of the effluent from the leaching and/or solid-liquid separation stages (4); (d) treatment of the effluents from stages (b) or (c) using an ion-exchange hybrid system (5) comprising at least one circuit for removal of impurities and at least one circuit for recovery of nickel and cobalt; (e) elution (6) of the ion-exchange resin used; (f) separation, purification, and recovery (7) of the nickel and cobalt.
The process, according to the invention, comprises the following stages: (a) processing (1) of the laterite ore (O) by crushing, scrubbing, attrition, separation, and high-intensity magnetic separation; (b) Leaching (2) of the non-magnetic fraction (CN) obtained form the previous stage (a); (c) optionally, neutralization (3) of the effluent from the leaching and/or solid-liquid separation stages (4); (d) treatment of the effluents from stages (b) or (c) using an ion-exchange hybrid system (5) comprising at least one circuit for removal of impurities and at least one circuit for recovery of nickel and cobalt; (e) elution (6) of the ion-exchange resin used; (f) separation, purification, and recovery (7) of the nickel and cobalt.
'Method for production of metallic cobalt from the raffinate from solvent extraction of nickel'. Said method comprises the following stages: (A) obtaining the raffinate from solvent extraction of nickel, for production of cobalt; (B) adding a sulfide precipitation agent to said raffinate, for cobalt sulfide and zinc sulfide precipitation; (C) removing all ammonia from the sulfidized pulp (solids and liquid); (D) subjecting the filtered solid - cobalt sulfide (and impurities) - to atmospHeric leaching; (E) reducing to a minimum the zinc concentration in the cobalt round, by means of solvent extraction with D2EPHA extractant diluted in Escaid 110 solvent or equivalent solvent, in any solvent extraction system comprising the required number of extraction, scrubbing, and stripping stages, with resident time of not less than 1 minute at each of the stages used; (F) performing nickel removal by ion exchange, for nickel purification; (G) adding sodium carbonate to the solution, for cobalt carbonate precipitation; (H) leaching the produced cobalt carbonate in a system that utilizes an acid, preferably sulfuric acid, and more preferably, the anolyte from cobalt electrolysis; (I) performing cobalt electrowinning so as to recover the cobalt from the solution in its metallic form; and (J) allowing the metallic cobalt to settle on insoluble stainless steel plates during the time required for production of the cobalt cathodes.
'LIQUID OR PULP AERATION DEVICE' that projects liquid or pulp (P) through a spreading nozzle on a chain curtain (C) and captures air bubbles from the liquid or pulp (P) while the fluid outflows through the curtain links (C) by gravity forming films by virtue of an interaction of the surface strain and wettability between the three surfaces in question. As far as the outflow is concerned, these films end up interacting between themselves capturing the remaining air between them, thus forming profuse bubbles, resulting in the formation of liquid or foaming pulp (P) by virtue of the chain discharge (C).
C22B 1/00 - Preliminary treatment of ores or scrap
C23C 18/12 - Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
B05B 1/00 - Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means
B05B 7/00 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
B05D 1/02 - Processes for applying liquids or other fluent materials performed by spraying
7.
A PROCESS FOR THE INSTANTANEOUS CONTROL OF PRECIPITATION OF NICKEL AND COBALT PRESENT IN THE LEACH LIQUOR, BY ADJUSTING THE PH OF THE SOLUTION
The present invention concerns a process for the instantaneous control of the precipitation of nickel and cobalt present in a leach liquor by adjustment of the pH-value. Said leach liquor is obtained by pressurized acidic leaching of laterite ores and additionally contains aluminium, ferric and ferrous iron and chromium among others. The process comprises the following steps: precipitation of aluminium, ferric and ferrous iron, chromium etc. by increasing the pH- value by adding a suitable reagent such as lime and/or limestone, following precipitation of nickel and cobalt by further increasing the pH-value of the liquor, finally separating the precipitate from the low-content nickel and cobalt solution. The nickel and cobalt precipitate can be used for further refinement. In order to keep the process conditions constant, the steps of increasing the pH-value are controlled simultaneously.
'AN ORE HEAP LEACHING PROCESS FOR METAL PRODUCTION WITH THE AID OF SOLAR ENERGY', involving ore crushing (1 ), followed by fines agglomeration (2), and then addition of sulfuric acid and/or additives (3) to produce the heap leach pile (4); next, said heap leach pile (4) receives the leaching solution (5), thereby originating a target metal-pregnant solution, which is stored in a reservoir (6) and then is subjected to a metal recovery stage (7), originating a target metal-poor solution (8), at which point a process stage is included, in which both the metal-poor solution reservoir (8) and the water (9) are heated by the solar energy collected by solar collectors (10), thereby providing the heating of the leaching solution (5) that is kept in a thermally insulated vessel to maintain the temperature and better utilize the collected energy.
comprising comminution (1), followed by pressure leaching (3), which may, or may not, be preceded by a baking stage (2); after the leaching stage (3), the resulting alkaline liquor is separated from the slurry by filtration (4), preferably vacuum filtration, and then is subjected to further processing for obtaining the target potassium salt; said process having a second variant involving a calcination step of the verdete slate (5) preceding the pressure leaching stage (3).
The present invention is directed to a hybrid process using ion ex- change resins in the selective recovery of nickel and cobalt of leaching effluents that is comprised of the steps of processing (1 ) the laterite ore (M), which is then treated through leaching (2) (either atmospheric or under pressure), considering solutions from the solid-liquid separation step of existing plants already in operation (2) as well, in a way that the downstream process comprises an ion exchange hybrid circuit, wherein the first ion exchange step (3) with resins (Re) exhibits specific selectivity conditions for the removal of iron, aluminum and copper and an increased pH, and the second ion exchange step (4) allows the removal of nickel and cobalt.
C22B 3/24 - Treatment or purification of solutions, e.g. obtained by leaching by physical processes, e.g. by filtration, by magnetic means by adsorption on solid substances, e.g. by extraction with solid resins
B01D 15/00 - Separating processes involving the treatment of liquids with solid sorbents; Apparatus therefor
B01J 39/00 - Cation exchange; Use of material as cation exchangers; Treatment of material for improving the cation exchange properties
B01J 45/00 - Ion-exchange in which a complex or a chelate is formed; Use of material as complex or chelate forming ion-exchangers; Treatment of material for improving the complex or chelate forming ion-exchange properties
C22B 3/42 - Treatment or purification of solutions, e.g. obtained by leaching by ion-exchange extraction
The present invention is directed to a hybrid process using ion ex- change resins in the selective recovery of nickel and cobalt of leaching effluents that is comprised of the steps of processing (1 ) the laterite ore (M), which is then treated through leaching (2) (either atmospheric or under pressure), considering solutions from the solid-liquid separation step of existing plants already in operation (2) as well, in a way that the downstream process comprises an ion exchange hybrid circuit, wherein the first ion exchange step (3) with resins (Re) exhibits specific selectivity conditions for the removal of iron, aluminum and copper and an increased pH, and the second ion exchange step (4) allows the removal of nickel and cobalt.
C22B 3/24 - Treatment or purification of solutions, e.g. obtained by leaching by physical processes, e.g. by filtration, by magnetic means by adsorption on solid substances, e.g. by extraction with solid resins
C22B 3/42 - Treatment or purification of solutions, e.g. obtained by leaching by ion-exchange extraction
B01D 15/00 - Separating processes involving the treatment of liquids with solid sorbents; Apparatus therefor
B01J 39/00 - Cation exchange; Use of material as cation exchangers; Treatment of material for improving the cation exchange properties
B01J 45/00 - Ion-exchange in which a complex or a chelate is formed; Use of material as complex or chelate forming ion-exchangers; Treatment of material for improving the complex or chelate forming ion-exchange properties
12.
PROCESS FOR EXTRACTION OF NICKEL, COBALT, AND OTHER BASE METALS FROM LATERITE ORES BY USING HEAP LEACHING AND PRODUCT CONTAINING NICKEL, COBALT, AND OTHER METALS FROM LATERITE ORES
The present invention embodies a process for extraction of nickel, cobalt, and other metals from laterite ores by heap leaching, and of the product obtained as well, characterized by the fact that it is comprised of crushing (I), agglomeration (II), stacking (III), and heap leaching (IV) stages, with this last stage being a continuous, counter--current, heap leaching system with two or more stages, comprised of two phases, one of which is composed of the ore (solute), and the other is composed of the leaching solution, or solvent, which are supplied at opposite ends of the series of stages and flow in opposite directions. Upon cessation of leaching in the last stage, its solute is removed and a new stage is introduced at the first position, formed by new ore (solute) to be leached by the solvent solution, which is introduced from the last stage, percolating or flowing through all the previous stages until it reaches the first stage, being separated if loaded with target metals (PLS).
The combined leaching process comprises a dissolution process of the soluble constituents of an ore by means of the combined execution of two or more serial leaching phases with the first phase comprising atmospheric leaching (AL) and the second one pressure leaching (HPAL). This combined process takes place when the intermediate size fraction (0.075-0.5 mm) (1) is submitted to atmospheric leaching (AL), ensuing an effluent with a high concentration of dissolved iron and aluminum as well as high residual acidity. This said effluent (3) is fed in the following acid pressure leaching (HPAL) phase of the fine size fraction (<0.075mm) (4) and at reusing free acidity, regenerating the sulfuric acid through iron and aluminum precipitation in a hydrolysis reaction, and bringing forth a considerable reduction in the addition of sulfuric acid.
C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
C25C 1/08 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese of nickel or cobalt
The combined leaching process comprises a dissolution process of the soluble constituents of an ore by means of the combined execution of two or more serial leaching phases with the first phase comprising atmospheric leaching (AL) and the second one pressure leaching (HPAL). This combined process takes place when the intermediate size fraction (0.075-0.5 mm) (1) is submitted to atmospheric leaching (AL), ensuing an effluent with a high concentration of dissolved iron and aluminum as well as high residual acidity. This said effluent (3) is fed in the following acid pressure leaching (HPAL) phase of the fine size fraction (ឬ0.075mm) (4) and at reusing free acidity, regenerating the sulfuric acid through iron and aluminum precipitation in a hydrolysis reaction, and bringing forth a considerable reduction in the addition of sulfuric acid.
C22B 9/00 - General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
C22B 3/06 - Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions
C25C 1/06 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese
C25C 1/08 - Electrolytic production, recovery or refining of metals by electrolysis of solutions of iron group metals, refractory metals or manganese of nickel or cobalt
15.
A PROCESS FOR ENRICHMENT OF ANATASE MECHANICAL CONCENTRATES IN ORDER TO OBTAIN SYNTHETIC RUTILE WITH LOW CONTENTS OF RARE EARTH AND RADIOACTIVE ELEMENTS
A process for obtaining synthetic rutile with low contents of rare earth and radioactive elements from anatase mechanical concentrates, comprising the following sequential operations: calcination (1) of the anatase concentrate in a fluidized bed or rotary kiln wherein hydrated iron oxides are converted into hematite after hydration water is removed, providing a reduction in the time required for next step; reduction (2) of the calcined product, in a fluidized bed or rotary kiln, using hydrogen, natural gas or any carbon based reducing agent such as metallurgical coke, charcoal, petroleum coke, graphite, among others, the result of which is the transformation of 15 allurgical coke, charcoal, petroleum coke, graphite, among others, the result of which is the transformation of hematite into magnetite; dry or wet low-intensity magnetic separation (3) of the reduced product, high-intensity, high-gradient magnetic separation (4) of the low-intensity non-magnetic fraction, extracting silicates, secondary phosphates, monazite, calzirtite, zircolinite and uranium and thorium-containing minerals; leaching (5) of the magnetic fraction of the high-intensity, high-gradient separation in agitated tanks or fluidized bed columns, with a solution providing solubilization of impurities rich in iron, aluminium, phosphates, magnesium, barium, calcium, strontium, rare earths, uranium and thorium; filtering of the leached product drying of the filtered product oxidation (6) of the dried product in the presence of a mixture of the following substances, alkali, metal sulphates (mainly lithium, sodium and potassium), alkali metal carbonates (mainly lithium, sodium and potassium), phosphoric acid (H3PO4) and, eventually, sodium chroride; quenching of the oxidized product in water or compressed air; leaching (7) of the queched product in agitated tanks or colums, filtering of the product from the second leaching (7) in a belt filter; and drying of the filtered product in a rotary or fluidized bed drier, dry, high-intensity, high-gradient magnetic separation (8) of the product of the second leaching, in rare-earth permanent magnet, discarding of the magnetic fraction and recovering the non-magnetic fraction as final product (P), that is, the synthetic rutile of interest.
The invention is directed to a material for coating iron ore pelletizing disks and drums and a constructive arrangement for pelletizing disks and drums that is comprised of a mixture of binders with ores (that may or not be ground) of the group consisting of iron, manganese or others, the inclusion of fluxes being also provided. The bottom (1) of the disk or drum (5) is coated with a cold cure coating material, vegetal oils, minerals and/or gel-forming products in order to form a bottom layer (2) that may or not be on the surface, and polyethylene plates (7) to aid in the separation of the fines from the pellets (6) can also be incorporated into the inner perimetral edge (6) of said pelletizing disk or drum (5).
