Recovery of nickel, cobalt, iron, silica, zinc and copper from laterite ore by sulfuric acid leaching

Abstract

A process for recovering nickel and cobalt values from nickel- and cobalt-containing laterite ores as an enriched mixed nickel and cobalt sulphide intermediate and for producing nickel and cobalt metal from the nickel and cobalt sulphide intermediate. The laterite ore is leached as a slurry in a pressure acid leach containing an excess of aqueous sulphuric acid at high pressure and temperature, excess free acid in the leach slurry is partially neutralized to a range of 5 to 10 g/L residual free HSOand washed to yield a nickel- and cobalt-containing product liquor, the product liquor is subjected to a reductant to reduce any Cr(VI) in solution to Cr(III), the reduced product liquor is neutralized to precipitate ferric iron and silicon at a pH of about 3.5 to 4.0, and the neutralized and reduced product liquor is contacted with hydrogen sulphide gas to precipitate nickel and cobalt sulphides. The precipitated nickel and cobalt sulphides can be leached in a water slurry in a pressure oxidation leach, the leach solution subjected to iron hydrolysis and precipitation, the iron-free solution contacted with zinc sulphide to precipitate copper, the iron- and copper-free solution subjected to zinc and cobalt extraction by solvent extraction to produce a nickel raffinate, the nickel raffinate contacted with hydrogen gas to produce nickel powder and the cobalt strip solution from the solvent extraction step contacted with hydrogen gas to produce cobalt powder.