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<p>The industrialization of ultralow-grade laterite nickel ore (&lt; 0.8 wt.% Ni) is critical for nickel supply in the new energy industry. The present research examined the optimization of high-pressure acid leaching (HPAL) of ultralow-grade ore with 0.68 wt.% Ni from Indonesia to evaluate its potential industrial application. This paper systematically discussed the influence of process parameters such as acid/ore ratio, temperature, leaching time, pulp density, particle size, and stirring speed, in addition to the economic cost related to acid consumption. Under optimized conditions of acid/ore ratio 0.22–0.24, temperature 230°C, 35–40% pulp density, particle size 200 mesh, stirring speeds between 300 and 400&#xa0;rpm, and leaching duration 30–45&#xa0;min, the process achieved 96% nickel and 99.9% cobalt recovery. Meanwhile, it effectively suppressed iron and aluminum dissolution with a value of 2.69% and 27.92%, respectively. Acid consumption was minimized to 30.22–32.61&#xa0;kg/ton, reducing cost to $1.71–$1.85 per ton ore with a savings of $0.07–$0.21 compared to industry benchmarks. This study is a pioneer focusing on and revealing the advantages of ultralow-grade ore, including reduced acid consumption costs and lower requirements on high-pressure reactors, making it a promising alternative for future industrial applications.</p>

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Optimization of High-pressure Acid Leaching for Nickel and Cobalt Recovery from Ultralow-Grade Laterite Ores

  • 期刊论文

  • 发表日期：

    2025年5月2日

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  • Irwan Syah Bana,
  • Wenjing Wan,
  • Leiting Shen

摘要

The industrialization of ultralow-grade laterite nickel ore (< 0.8 wt.% Ni) is critical for nickel supply in the new energy industry. The present research examined the optimization of high-pressure acid leaching (HPAL) of ultralow-grade ore with 0.68 wt.% Ni from Indonesia to evaluate its potential industrial application. This paper systematically discussed the influence of process parameters such as acid/ore ratio, temperature, leaching time, pulp density, particle size, and stirring speed, in addition to the economic cost related to acid consumption. Under optimized conditions of acid/ore ratio 0.22–0.24, temperature 230°C, 35–40% pulp density, particle size 200 mesh, stirring speeds between 300 and 400 rpm, and leaching duration 30–45 min, the process achieved 96% nickel and 99.9% cobalt recovery. Meanwhile, it effectively suppressed iron and aluminum dissolution with a value of 2.69% and 27.92%, respectively. Acid consumption was minimized to 30.22–32.61 kg/ton, reducing cost to $1.71–$1.85 per ton ore with a savings of $0.07–$0.21 compared to industry benchmarks. This study is a pioneer focusing on and revealing the advantages of ultralow-grade ore, including reduced acid consumption costs and lower requirements on high-pressure reactors, making it a promising alternative for future industrial applications.