Bhp Billiton Innovation Pty Ltd

Metalysis Limited

Bhp Billiton Ssm Technology Pty. Ltd.

Bhp Billiton Ssm Development Pty Ltd.

Ivan Ratchev

Steve Osborn

Les Strezov

Lazar Strezov

Houyuan Liu

Alexey Duarte

Gregory David Rigby

Kannappar Mukunthan

Harald Muller

Andrew Arthur Shook

Wolf Meihack

René Ignacio Olivares

Grant Caffery

Sergey Alexander Bliznyukov

Greg Rigby

Rene Ignacio Olivares

A method of smelting a nickel intermediate product in a smelter that contains a molten bath of metal and slag to produce a nickel product, the method comprising supplying the nickel intermediate product and a solid reductant to the smelter and smelting the nickel intermediate product to produce molten nickel, and controlling the chemistry of the slag so that the slag has (a) a high solubility for elements and compounds in the nickel intermediate product that are regarded as contaminants in the nickel product and (b) a liquidus temperature in the range of 1300-1700 C.

Production of nickel

A process for producing a metallic nickel product with a low iron content, that includes: (i) providing an acidic product liquor; (ii) subjecting the acidic product liquor to an ion exchange process to absorb the nickel and part of the iron; (iii) eluting the nickel and iron to produce an eluate containing the nickel and iron. (iv) neutralising the eluate to leave an iron depleted eluate; (v) neutralising the iron depleted eluate to cause precipitation of nickel hydroxide containing low iron; (vi) calcining the nickel hydroxide to convert it to nickel oxide; (vii) subjecting the nickel oxide to direct smelting in the presence of a reductant to produce a molten nickel phase; and (viii) refining the molten nickel phase by oxidation to produce a metallic nickel product with low iron content.

Production of metallic nickel with low iron content

A method of reducing a titanium oxide in a solid state in an electrolytic cell which includes an anode, a cathode formed at least in part from the titanium oxide, and a molten electrolyte which includes cations of a metal that is capable of chemically reducing the cathode titanium oxide, which method includes operating the cell at a potential that is above a potential at which cations of the metal that is capable of chemically reducing the cathode titanium oxide deposit as the metal on the cathode, whereby the metal chemically reduces the cathode titanium oxide, and which method is characterized by refreshing the electrolyte and/or changing the cell potential in later stages of the operation of the cell as required having regard to the reactions occurring in the cell and the concentration of oxygen in the titanium oxide in the cell in order to produce high purity titanium.

Reduction of metal oxides in an electrolytic cell

An electrolytic cell for electrochemically reducing metal oxide powders and/or pellets is disclosed. The cell includes a cathode () in the form of a plate that has an upper surface for supporting metal oxide powders and/or pellets. The plate is horizontally disposed or slightly inclined and has a forward end and a rearward end and is immersed in an electrolyte bath. The plate is supported for movement so as to cause metal oxide powders and/or pellets on the upper surface of the plate to move toward a forward end of the plate. The cell also includes a means for causing metal oxide powders and/or pellets to move over the upper surface of the plate toward the forward end of the cathode while in contact with molten electrolyte whereby electrochemical reduction of the metal oxide to metal can occur. A method of continuously or semi-continuously reducing metal oxide powders and/or pellets in the cell is also disclosed.

Electrochemical reduction of metal oxides

An electrochemical cell for electrochemical reduction of a metal oxide in a solid state is disclosed. The cell includes a molten electrolyte (), an anode () formed from carbon in contact with the electrolyte, a cathode () formed at least in part from the metal oxide in contact with the electrolyte, and a membrane () that is permeable to oxygen anions and is impermeable to carbon in ionic and non-ionic forms positioned between the cathode and the anode to thereby prevent migration of carbon from the anode to the cathode. The membrane includes a body () and a lining () on the surface of the body on the cathode side of the membrane. The lining is formed from a material that is inert with respect to dissolved metal in the electrolyte and is impermeable to the dissolved metal. An electrochemical method based on the cell is also disclosed.

Minimising carbon transfer in an electrolytic cell

A process for the production of ferro-nickel or nickel matte from a product liquor solution containing at least nickel, cobalt, iron and acid soluble impurities, said process including the steps of: (a) contacting the product liquor solution () containing the nickel, cobalt, iron and acid soluble impurities with an ion exchange resin (), wherein the resin selectively absorbs nickel and iron from the solution leaving the cobalt and the acid soluble impurities in the raffinate (); (b) stripping the nickel and iron from the resin with a sulfuric acid solution to produce an eluate () containing nickel and iron; (c) neutralising the eluate to precipitate a mixed nickel iron hydroxide product (); and (d) reducing and smelting the mixed nickel iron hydroxide product to produce ferro-nickel () or nickel matte ().

Production of ferro-nickel or nickel matte by a combined hydrometallurgical and pyrometallurgical process

A process for producing a ferronickel product from a mixed nickel iron hydroxide product, said process including the steps of: providing a mixed nickel iron hydroxide product; pelletising the mixed nickel iron hydroxide product to produce nickel iron hydroxide pellets; calcining the nickel iron hydroxide pellets to produce mixed nickel iron oxide pellets; and reducing the nickel iron oxide pellets with one or more reducing gases at high temperatures to produce ferronickel pellets.

Production of ferronickel

A process for electrochemically reducing a metal oxide, such as titania, in a solid state in an electrochemical cell that includes a bath of molten electrolyte, a cathode, and an anode, which process includes the steps of: a) applying a cell potential across the anode and the cathode that is capable of electrochemically reducing the metal oxide supplied to the molten electrolyte bath, b) continuously or semi-continuously feeding the metal oxide in powder and/or pellet form into the molten electrolyte bath, c) transporting the powders and/or pellets along a path within the molten electrolyte bath and reducing the metal oxide as the metal oxide powders and/or pellets move along the path, and d) continuously or semi-continuously removing metal from the molten electrolyte bath. Also disclosed and claims is an electrochemical cell for carrying out this process.

A method of reducing a metal oxide in a solid state, in an electrolytic cell, is provided, as is an electrolytic cell suitable for performing the method. The cathode of the electrolytic cell is formed at least in part from the metal oxide to be reduced, and the electrolyte includes cations of a metal that is capable of chemically reducing the cathode metal oxide. The method includes operating the cell at a potential that is above the potential at which cations of the reducing metal will deposit as metal on the cathode.

A method of manufacturing titanium or titanium alloy semi-finished or ready-to-use products is disclosed. The method includes forming shaped bodies of titanium oxide particles and positioning the shaped bodies is an electrolytic cell which includes: an anode, a cathode, and a molten electrolyte. The shaped bodies are positioned to form at least a part of the cathode. The electrolyte includes cations of a metal that is capable of chemically reducing titanium oxide. The method further includes reducing the titanium oxide to titanium in a solid state in the electrolytic cell so that the shaped bodies become shaped bodies of titanium sponge. Finally, the method includes processing the shaped bodies of titanium sponge to reduce the volume or at least one of the dimensions of the bodies thereby to form the semi-finished or ready-to-use products.

Method of manufacturing titanium and titanium alloy products

An electrolytic cell for reducing a beryllium oxide in solid state, and a method for achieving this reduction, are provided. The electrolytic cell and method employ an anode, a cathode formed in part from beryllium oxide, and a molten electrolyte which includes cations of a metal that is capable of reducing beryllium oxide. The reduction process involves operating the cell at a potential that is above a potential at which the reducing cations in the electrolyte will deposit as a metal on the cathode.

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Georgetown, Australia

Ivan Ratchev