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Huafei Nickel Cobalt (Indonesia) Co., Ltd. Smelter Pre-job Training

Overview of Huafei Nickel-Cobalt Hydrometallurgy Process

§1.1 Process flow of smelter

picture5.Smelter process flow chart

Huafei nickel-cobalt smelting process flow chart is as above5As shown, the whole smelting system is mainly composed of leaching, neutralization and impurity removal, products, tailings

The slag treatment consists of four sections. The procedures in each section are as follows:

1) leaching section: dense raw ore pulp→Pulp preheating→pressure leaching→Slurry flash transportation

2) Neutralization and impurity removal section: dense separation of leached pulp→Atmospheric pressure leaching and pre-neutralization→One-stage iron and aluminum removal→Two-stage iron and aluminum removal→Iron Alumin

Slag / Leaching SlagCCDcountercurrent washing

3) Product section: a section of immersion nickel cobalt→Second stage nickel cobalt→Product filter press→Product packaging

4) tailings treatment section:a) tailings neutralization→Tailings filter press→tailings dry pile→Filtrate treatment and sea discharge (before the tailings pond is completed)

b) tailings neutralization→Tailings transportation (after the construction of the tailings pond is completed)

§1.2Overview of the smelting process

1.2.1Slurry treatment

Raw ore pulp includes limonite pulp and magnesia pulp for neutralization (residual ore). Thickened limonite slurry after beneficiation

Retracted (38-40%) to the high-pressure acid leaching feed tank, and then pumped to the high-pressure

Preheating is carried out in the acid leaching pulp preheating system; the high-magnesium residual ore after beneficiation is also concentrated to a certain concentration and then directly pumped to the medium

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 Huafei Nickel Cobalt (Indonesia) Co., Ltd. Smelter Pre-job Training

React in the normal pressure leaching and pre-neutralization tank of the working section.

1.2.2high pressure acid leaching

The high-pressure acid leaching system is divided into six series, each series includes a slurry preheater feed pump, a three-stage slurry preheater, an autoclave feeding

Material pump, autoclave, three-stage flash tank, flash seal tank and tail gas scrubbing system, etc.

High-pressure acid leaching adopts the classic process model of "three-stage preheating-high-pressure leaching-three-stage flash evaporation".

The medium and high temperature preheaters are heated step by step from normal temperature to about205°CAfter that, it is pumped into the autoclave through the autoclave feeding;

The acid ore ratio is controlled by adding concentrated sulfuric acid and high-pressure steam into the autoclave, and the leaching time of the autoclave is about60min, autoclave operating temperature

250°C~255°C, operating pressure4.8MPa~5.1MPa,; the temperature of the leached pulp is about

105°C, after leaching the residual acid in the pulp30-40g/Lbetween.

1.2.3Dense separation of leaching pulp and leaching slagCCDwashing

Dense separation of leaching pulp and leaching slagCCDWashing is divided into two series, each series consists of1Taiwan leached pulp thickener,

5Taiwan leach residueCCDAnd supporting tank pump composition.

The pulp is pumped to the leaching pulp thickener through the flash seal tank delivery pump, and the leaching pulp thickener consists of2Taiwan φ42000×

6000(TT) thickener composition, underflow solid content≥50%, sent to the leach residueCCDThickener, the overflow is sent to atmospheric leaching

Tank for the next process reaction.

The underflow of the leach pulp thickener consists of5leaching residue CCDThe thickener completes the countercurrent washing treatment, and the leached pulp is thickened

Machine underflow enters firstCCD1, whose bottom flow enters in turnCCD2~CCD5,CCD5The underflow is sent to the tailings neutralization process.CCD

The washing water for countercurrent washing is nickel hydroxide and cobalt precipitation poor solution, and the washing ratio is about2.5:1(Washing water weight: weight of solids in thickener underflow

volume), washing water fromCCD5join in,CCD2~CCD5The overflow of the thickener is sent to the upper washing thickener as washing water, so that

Complete countercurrent washing of leach residue.CCD1The overflow is sent to the process of neutralizing and removing iron and aluminum.

1.2.4Atmospheric pressure leaching, pre-neutralization and removal of iron and aluminum

Circular leaching is mainly the leachate obtained by densely separating the leached pulp after flashing in an autoclave. The residual acid in the solution

To leach the second-stage iron-removing aluminum slag and the second-stage nickel-cobalt precipitation slag to increase the nickel leaching rate.

After the second-stage iron-aluminum slag and nickel-cobalt slag are leached, the residual acid is used to leach magnesia ore, saving limestone and increasing nickel-cobalt production.

1.2.5Thick separation of iron-aluminum slag and iron-aluminum slagCCDwashing

A section of iron and aluminum dense separation consists of2Consisting of a thickener system, the overflow is sent to the second-stage iron and aluminum removal process, and the underflow (solid content is about

35~40%) pumped to the iron-aluminum slagCCD1in progress6The cascaded thickener is used for countercurrent washing. The washing water comes from the second stage nickel and cobalt concentration

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The secret machine overflow is obtained after acidification, and the washing ratio is controlled at2~2.5around, the washing efficiency is in99%above. go through6classCCD

After washing, the underflow concentration reaches45%above, and then pumped to the tailings neutralization tank forpHvalue adjustment.

The second-stage iron and aluminum dense separation consists of3It consists of a thickener system, the overflow is used as a section of washing water for removing iron and aluminum, and the underflow returns to norma

Leaching process.

1.2.6Nickel Cobalt Hydroxide Precipitation

Hydroxide precipitation adopts two-stage precipitation method, and one-stage nickel hydroxide precipitation uses sodium hydroxide as precipitant to make the solution

Middle~90%Nickel and cobalt form hydroxide precipitation; after a period of precipitation, the slurry is sent to a thickener for liquid-solid separation, and part of the underflow is returned for

as seed crystals, and the rest are packaged as products after washing and filtering. The overflow of the first stage of the thickener is sent to the second stage of nickel and cobalt precipitation, and lime milk is used as the precipitation

After the sedimentation slurry is densely separated, part of the underflow is used as a seed crystal, and the rest is returned to the circulating leaching tank to recover nickel, cobalt, etc.

valuable metals. The nickel and cobalt overflow in the second stage is sent to the barren liquid storage tank, partly used as high-pressure acid leaching tail gas washing water, and partly used as leaching slag

CCDWashing water, part of which is acidified and used as iron-aluminum slag washing water, part of which is used as limestone slurry, lime milk preparation and hydrogen oxidation

Sodium is diluted with water, and the rest is discharged after deep removal of manganese. The main reactions are as follows (M = Ni,co,mn,Mg):

MSO4+2NaOH→M(OH)2↓+Na2SO4
MSO4+Ca(OH)2+2H2O→M(OH)2↓+CaSO4• 2H2O↓

1.2.7tailings neutralization

In order to meet the environmental protection discharge requirements, the wastewater and waste residues of smelters need to be treated.CCD6Underflow, high pressure pickling solution,

Part of the second-stage nickel and cobalt dense overflow is mixed with other waste water from the smelter, and then compressed air is introduced to oxidize the manganese. At the same time, stone

gray milk adjustmentpHValue, so that heavy metal impurity elements such as manganese are deeply precipitated, and after the tail liquid is neutralized, the pulp is thickened and then filtered as waste residue

and waste discharge. The main reactions are as follows:

Fe2(SO4)3+3Ca(OH)2+3H2o 2Fe(OH)3↓+3CaSO4ꞏ2H2O↓

NiSO4+Ca(OH)2+2H2o Ni(OH)2↓+CaSO4ꞏ2H2O↓

CoSO4+Ca(OH)2+2H2o Co(OH)2↓+CaSO4ꞏ2H2O↓

MgSO4+Ca(OH)2+2H2o Mg(OH)2↓+CaSO4ꞏ2H2O↓

MnSO4+2Ca(OH)2+O2+2H2o MnO2+2CaSO4ꞏ2H2O↓

1.2.8Tailings treatment

The Huafei Nickel-Cobalt Wet Process Project processed about2080Ten thousandt/a, the product is nickel hydroxide intermediate product (MHP),

The final waste residue volume of the project is2584Ten thousandt/a(Dry basis), this part of waste residue mainly comes from high pressure acid leaching leaching residue, neutralization and removal of iron and aluminum slag

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 Huafei Nickel Cobalt (Indonesia) Co., Ltd. Smelter Pre-job Training

and the mixed slag after the neutralization of manganese-containing waste liquid in the system. Before the construction of the tailings dam is completed, the comprehensive consideration of the project will first take a temporary me

That is to say, the slurry after tailings neutralization is first sent to the tailings filter press workshop by multi-stage centrifugal pump, and the dry residue is backfilled with waste liquid on site.

After treatment, the tailings slurry will be directly pumped to the tailings after the construction of the tailings pond is completed.

Storage of mines.

1) waste residue situation

The system high-pressure acid leaching leaching slag, neutralization and removal of iron and aluminum slag, and mixed slag produced after neutralization of the system’s manganese-containing waste liquid are the tailing

Solid density of slag and tailings3.2~3.8t/m3, solid concentration45%w/w,granularityP80=100um,pHvalue in8.1~8.5.

The main components of tailings solids are shown in the table3-1, see the table for the composition of the waste liquid in the slag3-2shown.

surface1-1.Main components of tailings solids (%w/w)

Slag containing water Ni co Fe Mg Al mn Si Cr S Ca

55 0.12 0.02 34.87 1.18 2.74 0.59 6.60 0.81 4.95 4.79

surface1-2.The main components of the waste liquid in the tailings (mg/L)

Ni co Fe Mg Al mn Cr

<0.5 <0.4 <1 12585 <1 <0.1 <1

2) Solid waste properties of waste residue

According to Indonesian government leaching procedure for slag toxicity characteristics (TCLP)Requirements, using sodium acetate buffer solution

leach.

1.2.9tailings dam

1) storage capacity

The tailings dam is proposed to be located in the valley around the wet process project. According to the amount of slag discharged outside the smelting, according to the tailings dam10Year service period, total dry resid

The amount is1292010,000 tons, the average bulk dry bulk weight of tailings is1.2Count, storage capacity utilization factor0.75, the required storage capacity of the tailings dam is14400

Ten thousand cubic meters.

2) ore discharge method

Tailings drawing adopts the form of surrounding ore drawing, combined with the layout of the backwater setting, it is used in front of the dam, on the north and west sides of the tailings dam

For scattered ore, in order to meet the requirements of backwater clarification span, no ore drawing points are set within a certain range of the flood discharge area of the backwater area.

3) slag dam

The supporting tailings reservoir of the Huafei project adopts a one-time dam construction method of local natural materials, and the slag retaining dam is designed to be impermeable

The dam will be heightened later using the natural material downstream method. In order to reduce the one-time investment, the slag dam is divided into

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 Huafei Nickel Cobalt (Indonesia) Co., Ltd. Smelter Pre-job Training

2period of construction.

The tailings silo adopts an anti-seepage design, and the earth and rocks generated during the excavation and leveling of the site and the earth and rocks generated during the leveling of the dressing and smelting site

If it meets the requirements of dam materials, it can be used for dam construction.

4) initial dam and late dam

Initial dam meets smelting slag dump5annual requirement, storage capacity720010,000 cubic meters, maximum dam height60m, the amount of dam construction1500Wan Li

square; the total storage capacity of the later dam formation1440010,000 cubic meters, pit height90m, the amount of dam construction1820Ten thousand cubic meters.

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