Masters Research - Master of Science / The jarosite group of compounds are yellow/brown clay like substances, both naturally occurring and synthetically produced in metallurgical processes. Jarosites have the structure MFe3(SO4)2(OH)6, where M can be numerous elements or compounds, most often potassium or sodium. The term jarosite refers specifically to the potassium form of the compound, but is synonymous with the whole group of compounds, often leading to confusion. In nature, jarosites can be associated with acid mine drainage and acid sulphate soils as an intermediate product of the oxidation of pyrite and other iron/sulphur bearing minerals. In industry, jarosites are used in metallurgical processes, synthetically produced to precipitate an easily filterable form of solid iron. Jarosites have properties that make them a chemically unstable solid. Upon decomposition the jarosite group of compounds will generate sulphuric acid. A literature review found many references to jarosites, their stability, methods of conversion to iron oxides, methods to extract reusable materials and environmental concerns. Most methods of recycling were unsuccessful. Accelerated conversion of jarosites to a form of iron oxide was a successful method of mitigating the risk of future acid generation. There were numerous specific ways of completing this task. The BHP Billiton patented nickel atmospheric leach process generates natrojarosite (sodium form of the compound) as a by-product, when extracting nickel from lateritic ores. The by-product of this process was tested for stability to understand the decomposition process. Accelerated decomposition of natrojarosite was attempted using limestone and hydrated lime at 90OC. Limestone did not react with the natrojarosite. Hydrated lime caused extensive dissolution of sodium and sulphur from the solid. However XRD analysis still reported natrojarosite as the solid material, suggesting incomplete decomposition and the formation an amorphous form of iron oxide not detected by XRD. Further decomposition tests were completed using elevated temperatures and pressures in an autoclave. Natrojarosite was not detectable in the solid phase after treatment at a temperature of 212OC, converting to haematite at temperature above 150OC. The stability of natrojarosite was measured using a number of methods on two natrojarosite samples sourced from the atmospheric leach process. The methods used were batch agitation, column testing and permeability testing. The aim was to provide a holistic result for the stability of natrojarosite if stored in a waste facility. Results obtained were compared against the standard TCLP test and found to be a more accurate method for measuring the stability of natrojarosite. The tests are more time consuming than TCLP testing but showed that natrojarosite was capable of decomposing to form sulphuric acid with time. This result was not obtained from TCLP tests, which suggested the solid material was stable. It was also found that salt water stabilised natrojarosite. Decomposition occurred in 40 and 80 days respectively, for two natrojarosite samples tested in deionised water. There was no evidence of decomposition after 150 and 280 days respectively for the same two samples. The common ion theory is thought to stabilise the natrojarosite which decomposes in an equilibrium reaction. Excess ions present in solution decrease the propensity for the solid to decompose. The two natrojarosite samples tested varied in calcium concentration. Limestone and hydrated lime were added to the natrojarosite during the nickel extraction process. Gypsum is theorised to form an impermeable layer around the natrojarosite, increasing the stability of the compound. Gypsum is sourced from the neutralisation reaction between limestone or hydrated lime and the acid generated from natrojarosite decomposition.

With China’s continuing economic boom, the demand for nickel has seen unprecedented growth over the past 10 years. Most of the world’s nickel is present in nickel laterite deposits. These high volume, low grade deposits are now being exploited and processed. An understanding of nickel laterite rheology and the ability to obtain meaningful rheological data is essential to process intensification and stability. / The properties and physical characteristics of 8 industrial nickel laterite slurries as well as two alumina slurries were examined using various rheological techniques. The samples chosen covered a wide range of physical conditions such as differing pH, particle size distributions, solids densities and mineralogy as well as country and deposit of origin. The rheological parameters investigated were the yield stress and shear stress vs. shear rate of the particulate slurries. Considerable attention was focused on the techniques used in shear stress vs. shear rate characterisation, including capillary rheometry, smooth and roughened cup and bob rheometry and the vane in infinite medium technique. / This work confirmed the finding of previous works, showing nickel laterite slurry rheological behaviour ranging from time independent to thixotropic to rheopectic. It found the vane in infinite medium technique highly suitable for testing nickel laterites at process relevant yield stresses. This technique gave data that correlated well with vane yield stresses and capillary rheometry data. Cup and bob tests showed significant slip at lower shear rates. In a number of cases, the cup and bob techniques also showed erroneously high stresses at higher shear rates. / The vane yield stress was found to be a fast and accurate method for monitoring nickel laterite sample aging and the samples tested exhibited 100 Pa yield stresses at solids fractions ranging from 0.389 to 0.524. Blending of nickel laterites was found to be nonlinear, and confirmed that characterisation at various blend ratios is necessary if blending is to be utilised during production.

A systematic research study was carried out in order to characterize the rheology of concentrated slurries prepared from eight nickel laterites. The experiments were carried out using a rotational viscometer, and the behavior of the laterites was evaluated in terms of the apparent viscosity and yield stress obtained through flow curve modeling. An attempt was made to correlate the results obtained for the laterite samples with data obtained for model single mineral systems as well as for model mixed mineral systems. In combination with detailed mineralogical characterization of the laterite samples, all the rheological results allowed a rheology-based laterite classification system to be proposed. Accordingly, the laterite samples gave the following responses: the SAPSIL samples (high-quartz) generally producedl ow yield stress values, the SAPFE samples (high-iron) were characterized by intermediate to high yield stress values, while the SAP samples (saprolite) gave the highest yield stress values. Interestingly, these dominant rheological responses of laterites could actually be predicted based on rheological tests carried out on model mineral suspensions (particularly goethite and quartz). Since the rheology of fine mineral suspensions is largely determined by the surface properties (surface charge) of the particles, a series of electro-acoustic measurements were also performed on model minerals and laterite samples to analyze the surface charge characteristics of the tested samples. It was demonstrated that the current electro-acoustic theory developed for single mineral systems can readily be used for modeling the behavior of mixed mineral systems. The modeling and experimental data agreed exceptionally well when constituent minerals were of the same surface charge under given pH. Clear but rather small deviations between experiment and theory were observed under conditions when the minerals were oppositely charged. This observation strongly suggested that inter-particle aggregation was most likely responsible for the observed discrepancies. Overall, the results of this thesis show that laterite slurries exhibit a wide range of rheological responses due to highly variable mineralogy, differences in particle size distributions, and difference in the surface properties of the many constituent minerals. It also shows that the surface properties of the minerals relates to rheology.

A systematic research study was carried out in order to characterize the rheology of concentrated slurries prepared from eight nickel laterites. The experiments were carried out using a rotational viscometer, and the behavior of the laterites was evaluated in terms of the apparent viscosity and yield stress obtained through flow curve modeling. An attempt was made to correlate the results obtained for the laterite samples with data obtained for model single mineral systems as well as for model mixed mineral systems. In combination with detailed mineralogical characterization of the laterite samples, all the rheological results allowed a rheology-based laterite classification system to be proposed. Accordingly, the laterite samples gave the following responses: the SAPSIL samples (high-quartz) generally producedl ow yield stress values, the SAPFE samples (high-iron) were characterized by intermediate to high yield stress values, while the SAP samples (saprolite) gave the highest yield stress values. Interestingly, these dominant rheological responses of laterites could actually be predicted based on rheological tests carried out on model mineral suspensions (particularly goethite and quartz). Since the rheology of fine mineral suspensions is largely determined by the surface properties (surface charge) of the particles, a series of electro-acoustic measurements were also performed on model minerals and laterite samples to analyze the surface charge characteristics of the tested samples. It was demonstrated that the current electro-acoustic theory developed for single mineral systems can readily be used for modeling the behavior of mixed mineral systems. The modeling and experimental data agreed exceptionally well when constituent minerals were of the same surface charge under given pH. Clear but rather small deviations between experiment and theory were observed under conditions when the minerals were oppositely charged. This observation strongly suggested that inter-particle aggregation was most likely responsible for the observed discrepancies. Overall, the results of this thesis show that laterite slurries exhibit a wide range of rheological responses due to highly variable mineralogy, differences in particle size distributions, and difference in the surface properties of the many constituent minerals. It also shows that the surface properties of the minerals relates to rheology.

A systematic research study was carried out in order to characterize the rheology of concentrated slurries prepared from eight nickel laterites. The experiments were carried out using a rotational viscometer, and the behavior of the laterites was evaluated in terms of the apparent viscosity and yield stress obtained through flow curve modeling. An attempt was made to correlate the results obtained for the laterite samples with data obtained for model single mineral systems as well as for model mixed mineral systems. In combination with detailed mineralogical characterization of the laterite samples, all the rheological results allowed a rheology-based laterite classification system to be proposed. Accordingly, the laterite samples gave the following responses: the SAPSIL samples (high-quartz) generally producedl ow yield stress values, the SAPFE samples (high-iron) were characterized by intermediate to high yield stress values, while the SAP samples (saprolite) gave the highest yield stress values. Interestingly, these dominant rheological responses of laterites could actually be predicted based on rheological tests carried out on model mineral suspensions (particularly goethite and quartz). Since the rheology of fine mineral suspensions is largely determined by the surface properties (surface charge) of the particles, a series of electro-acoustic measurements were also performed on model minerals and laterite samples to analyze the surface charge characteristics of the tested samples. It was demonstrated that the current electro-acoustic theory developed for single mineral systems can readily be used for modeling the behavior of mixed mineral systems. The modeling and experimental data agreed exceptionally well when constituent minerals were of the same surface charge under given pH. Clear but rather small deviations between experiment and theory were observed under conditions when the minerals were oppositely charged. This observation strongly suggested that inter-particle aggregation was most likely responsible for the observed discrepancies. Overall, the results of this thesis show that laterite slurries exhibit a wide range of rheological responses due to highly variable mineralogy, differences in particle size distributions, and difference in the surface properties of the many constituent minerals. It also shows that the surface properties of the minerals relates to rheology. / Applied Science, Faculty of / Mining Engineering, Keevil Institute of / Graduate

Leaching is the most widely used process for extraction of nickel metal from lateritic ores. In this study, nickel extraction from Manisa-G&ouml / rdes region laterites by hydrochloric acid leaching is aimed. The mineralogical analysis of sample showed that hematite, goethite, dolomite, quartz and smectite are the main minerals in the ore. Attrition scrubbing, cycloning and magnetic separation with permroll were used as preconcentration processes but results were unsatisfactory. HCl leaching experiments were conducted both at room temperature and at elevated temperatures. The effects of various parameters such as leaching duration, particle size, concentration of HCl, pulp density, Cl- concentration and temperature on nickel recovery were examined. The results showed that under the optimised leaching conditions (particle size: 100 % -1 mm, HCl concentration: 3 N, leaching duration: 3 hours, leaching temperature: 100 oC, pulp density: 1/30 solid to liquid ratio by volume) it was possible to extract 87.26 % of nickel in the ore.

ENGLISH ABSTRACT: Leaching of nickel laterite was conducted with a solution of ammonia and ammonium carbonate in a closed vessel. The vessel used in this study was designed to leach and perform solid-liquid separation at the same time. For solid-liquid separation, stainless steel sintered metal filter media were used. The sintered metal filter medium was selected for its high strength to withstand pressure, chemical resistance to caustic solution and back flushing properties. Optimum leaching conditions were determined by varying temperature, ammonia concentration, ammonium carbonate concentration and oxygen pressure. After leaching and filtration, the pH of the leach liquor was measured and samples were analyzed for dissolved metals (Ni, Fe and Co) using atomic absorption spectrophotometry. The most significant variable effect on leaching of nickel was the ammonia concentration. The maximum dissolution of nickel from the unroasted ore was 11.90% at 4 M NH3, 100oC, 2 M (NH4)2CO3 and 2 bar O2 pressure. Optimization from the leaching data was done using response profiling and desirability in Statistica software. Optimum leaching conditions were determined to be 3 M NH3, 2 M (NH4)2CO2, 100oC and 2 bar O2 pressure. The mineralogy of the ore before and after leaching was studied to understand why nickel extraction from unroasted ore was poor. XRF analysis of solids after leaching showed that iron, silicon, and magnesium remained the same. The only metal which showed significant decrease from solids was nickel. XRD analysis of solids after and before leaching showed that most mineral phases present in the ore are not affected by the leaching solution. SEM with EDS detection was used to determine nickel distribution within the ore. The results showed that nickel is mostly associated with iron. The iron is surrounded by magnesium and silicon. Silicate minerals do not react with ammonia and ammonium carbonate solution. From filtration experiments, the filtration differential pressure had no significant effect on the filtration rate. An average filtration rate of 0.29±0.07 ml/min.cm2 was obtained. The filtration rate from these experiments was very low. The main reason was due to quick pore clogging of sintered metals. Pore clogging was found to be mainly on the surface of the filter medium. Laterites have been found to have low permeability due a lot of clay present in the ore. Rheological studies on this ore showed that the ore has shear thickening behavior. However, a very clear filtrate was obtained. After each leach and filtration experiment, the sintered metals was unblocked by back flushing with water and air. Back flushing was successful because all 18 experiments were carried out using the same sintered filter medium. The effect of roasting the ore prior to leaching was investigated using optimum conditions obtained when leaching the unroasted ore. There was a slight improvement in nickel extraction when the ore was roasted. The average percentage extraction of nickel from 3 experimental runs was 19.25%±0.19 at 100oC, 3M NH3, 2M (NH4)2CO3, and 5 bar oxygen pressure. Some part of nickel in the ore was unextractable due to association of nickel with recrystallized silicate minerals in the reduced ore. Roasting improved permeability of the ore. The filtration rate improved significantly after roasting the ore. The average filtration rate was 2.60±0.05 ml/min.cm2. Dissolution kinetics of the unroasted and roasted saprolitic laterite were investigated with regard to the effects of temperature, ammonia concentration, ammonium carbonate concentration, and oxygen pressure. For the unroasted ore, it was found that dissolution rate and degree of nickel extraction increases with increasing temperature. Increase in ammonia concentration improves the degree of nickel extraction. Nevertheless, nickel extraction does not depend entirely on ammonia concentration because even when ammonia concentration is high and ammonium carbonate concentration is zero nickel extraction is low. An increase in ammonium carbonate concentration also increases the degree of nickel extraction. Ammonium carbonate is critical for the extraction, since ammonium ions in the solution prevent hydrolysis of the nickel ammine complex. Oxygen did not have a significant effect on the degree of nickel extraction. The leaching of nickel laterite was found to be a two stage leaching process. In the first stage, the dissolution of nickel is faster but after 15 minutes, the reaction rate is reduced. The reaction rate is reduced by inert minerals which host nickel. These minerals contain iron magnesium and silicon. The fast dissolution of nickel in the first stage represents leaching of free nickel in the ore. The data for the second stage of leaching was analyzed by the shrinking core model, and the results suggested that the dissolution rate is controlled by mixture kinetics (ash layer diffusion and surface reaction control). The activation energy for the dissolution reaction was calculated as 56.5 KJ/mol. The reaction order with respect to ammonia and ammonium carbonate were determined to be 0.3 and 0.26 respectively. For the roasted ore, the highest degree of nickel extraction was obtained at 60oC, 3M NH3, 2M (NH4)2CO3, and 5 bar oxygen pressure. The percentage extraction under these conditions was 28.7%. Temperature did not have a significant effect on the leaching rate. An increase in NH3 and (NH4)2CO3 increased the final extraction of nickel but did not have any effect on leaching rate in the first stage of leaching. In the absence of ammonium carbonate, nickel extraction is almost zero. The experimental data did not give linear fit to the shrinking core models investigated for the unroasted ore. The reason for this could be due to the sampling time interval which was too far apart, or the leaching behavior of roasted nickel is complicated and cannot explained by shrinking core model alone. Leaching experiments demonstrate that for a high degree metal extraction and improved reaction kinetics with ammonia and ammonium carbonate, the solution temperature should be high (>100oC) for the unroasted ore. In order to leach at high temperature with ammonia and ammonium carbonate a closed vessel is required to prevent reagent loses. The reaction kinetics showed that the reaction is controlled mostly by ash layer diffusion; this indicates that a low degree of nickel extraction in the unroasted saprolitic laterite is due to inert minerals (ash layer) which host nickel within the ore. In order to obtain a high degree of nickel extraction, the ore needs to be roasted under reducing conditions. Roasting conditions need to be carefully controlled to ensure high dissolution of nickel. In fact optimum roasting conditions which will give maximum dissolution of nickel, must be determined before working with the bulk of the ore. / AFRIKAANSE OPSOMMING: Logingstoetse van saprolitiese lateriet met 'n oplossing van ammonia en ammonium karbonaat is gedoen in 'n druk houer. Die logingsvat vir hierdie studie is ontwikkel om die loging sowel as die vloeistof – vastestof skeiding te doen. Gesinterde metaal filter medium was gebruik vir die vloeistof – vastestof skeiding aangesien dit die volgende eienskappe vertoon; die vermoë om druk te weerstaan, die chemiese weerstand teen bytsoda oplossing, asook voordelige terugspoel eienskappe. Optimum loogkondisies is bepaal deur die temperatuur, ammoniak konsentrasie, ammonium karbonaat konsentrasie, en suurstof druk te varieer. Na loging en filtrasie is die pH van die loogvloeistof gemeet en monsters is deur atoom absorpsie spektrofotometrie geanaliseer vir opgeloste metale (Ni, Fe en Co). Die veranderlike wat die grootste effek op die loging van nikkel gehad het was die ammoniak konsentrasie. Die maksimum herwinning van nikkel van uit ongeroosterde erts was 11.9 % by 4 M NH3, 100 oC, 2 M (NH4)2CO3 en 2 bar O2 druk. Optimisering van die loogdata is gedoen deur die respons profiel te analiseer met Statistica sagteware. Optimum loogkondisies was bepaal as 3 M NH3, 2 M (NH4)2CO2, 100 oC en 2 bar O2 druk. Die mineralogie van die erts voor en na loging is bestudeer om te bepaal waarom die nikel opbrengs van ongeroosterde erts so laag was. XRF analise van die vastestof na loging het gewys dat yster, silikon en magnesium nie deur loging affekteer is nie. Slegs nikkel het 'n merkwaardige afname getoon. XRD analsiese van die vastestof voor en na loging wys dat die meeste mineraal fases teenwoordig in die erts nie deur die loogoplossing affekteer is nie. SEM met EDS deteksie is gebruik om die nikkel verspreiding in die erts te bepaal. Die resultate wys dat nikkel meestal met yster assosieer. Die yster is omring deur magnesium en silikon. Silikaat minerale reageer nie met ammoniak en ammonium karbonaat oplossing nie. In filtrasie eksperimente is daar gevind dat die filtrasie differensiële druk geen noemenswaardige effek op die filtrasie tempo gehad het nie. Die gemiddelde filtrasietempo was 0.29+0.07 ml/min.cm2. Die filtrasie tempo van hierdie eksperimente was baie laag, hoofsaaklik as gevolg van blokkasie van porieë van die sinter metaal filter medium. Dit is gevind dat blokkasie van porieë hoofsaaklik op die oppervlak van die filter medium plaasvind. Lateriedes toon 'n lae deurlaatbaarheid as gevolg van die erts se hoë klei inhoud. Rheologiese studies op hierdie erts wys dat die erts skuif verdikking (“shear thickening”) gedrag vertoon. 'n Baie helder filtraat is egter verkry. Die gesinterde metale is na elke loog en filtrasie eksperiment skoongemaak deur terugspoeling met water en lug. Hierdie procedure was suksesvol, aangesien al 18 eksperimente met dieselfde filter medium uitgevoer is. Die effek van erts roostering voor loging is ondersoek by die optimum kondisies wat verkry was vir die loging van ongeroosterde erts. Nikkel ekstraksie het effens verbeter met geroosterde erts. Die gemiddelde persentasie ekstraksie van nikkel van drie eksperimentele lopies was 19.25 % + 0.19 by 100 oC, 3 M NH3, 2 M (NH4)2CO3, en 5 bar suurstofdruk. 'n Gedeelte van die nikkel in die erts was onherwinbaar as gevolg van die assosiasie van nikkel met her-gekristaliseerde sillikaat-minerale in die gereduseerde erts. Die porositeit van die erts is verbeter deur dit te rooster. Die filtrasie tempo het merkwaardig verbeter nadat die erts gerooster is. Die gemiddelde filtrasie tempo was 2.6+0.05 ml/min.cm2. Kinetika vir die oplossing van ongeroosterde en geroosterde saprolitiese lateriet is ondersoek, met in ag geneem die effekte van temperatuur, ammonia konsentrasie, ammonium karbonaat konsentrasie en suurstofdruk. Vir ongeroosterde erts is gevind dat die oplossingstempo en graad van nikkel ekstraksie toeneem met toenemende temperatuur. Toename in ammoniak konsentrasie lei tot 'n toename in nikkel ekstraksie, maar nikkel ekstraksie is nie alleenlik afhanklik van ammoniak nie. 'n Toename in ammonium karbonaat konsentrasie lei ook tot 'n toename in nikkel ekstraksie. Ammonium karbonaat is krities vir die ekstraksie, aangesien ammonium ione in die oplossing die hidrolise van die nikkel-amien kompleks verhoed. Suurstof het nie 'n merkwaardige effek op die totale nikkel ekstraksie gehad nie. Vir die bepaling van reaksie kinetika is 100˚C gebruik as die logingstemperatuur. Die loging van saprolitiese nikkel lateriet vind in twee stadia plaas. In die eerste fase is die oplossing van nikkel vinnig, maar na 15 minute neem die reaksietempo af. Die reaksietempo word verlaag deur inerte minerale wat teenwoordig is in die nikkel erts. Hierdie minerale bevat yster, magnesium en silikon. Die vinnige oplossing van nikkel in die eerste fase verteenwoordig die loging van vry nikkel in die erts. Die data vir die tweede stadium is geanaliseer deur die krimpende kern model, en die resultate dui aan dat die oplossingstempo deur 'n gemengde meganisme beheer word (as laag diffusie en oppervlak reaksie beheer). Die aktiveringsengergie vir die oplossingsreaksie was bereken as 56.5 kJ/mol. Die reaksieorde ten opsigte van ammoniak en ammonium karbonaat is onderskeidelik bepaal as 0.3 en 0.26. Die hoogste graad van nikkel ekstraksie vir die geroosterde erts is verkry by 60oC, 3 M NH3, 2 M (NH4)2CO3, en 5 bar O2 druk. Die persentasie ekstraksie by hierdie kondisies was 28.7 %. Temperatuur het nie 'n merkwaardige effek op loogtempo gehad nie. 'n Toename in NH3 en (NH4)2CO3 het die graad van nikkel ekstraksie laat toeneem, maar het nie enige effek op die loogtempo gehad nie. In die afwesigheid van ammonium karbonaat het byna geen nikkel ekstraksie plaasgevind nie. Die eksperimentele data het nie 'n lineêre passing vir die krimpende kern model soos vir die ongeroosterde erts ondersoek gegee nie. Die rede hiervoor is dat die monsternemings interval te groot was, of dat die logings karakteristiek van geroosterde nikel gekompliseerd is en nie alleen deur die krimpende kern model voorspel kan word nie. Logings eksperimente wys dat die temperatuur hoog moet wees (> 100 oC) om 'n hoë graad van nikkel ekstraksie te verkry met die ongeroosterde erts. 'n Geslote reaktor word benodig om by 'n hoë temperatuur met ammoniak en ammonium karbonaat te loog om reagens verliese te verhoed. Die reaksie kinetika word grootliks deur aslaag diffusie beheer. Hieruit kan gesien word dat 'n lae graad van nikkel ekstraksie uit die ongeroosterde saprolitiese lateriet die gevolg is van nie-reaktiewe minerale (aslaag) waarin die nikkel binne die erts bevat word. Om 'n hoë graad van nikkel ekstraksie te verkry moet die erts onder reduserende kondisies gerooster word. Rooster kondisies moet versigtig beheer word om hoë oplossing van nikkel te verseker. Optimum rooster kondisies om maksimum nikkel oplossing te verkry, moet bepaal word voordat daar met groter hoeveelhede erts gewerk kan word.

Níquel laterítico compõe 70% das reservas disponíveis do metal. A produção de níquel a partir dessas reservas representa 40%, dos quais é possível extrair também cobre e cobalto. Isso ocorre devido ao alto teor de impurezas, principalmente ferro. Com a crescente demanda desses metais, o uso das reservas de lateritas de níquel passou a ser mais profundamente investigado, assim como o desenvolvimento de processos hidrometalúrgicos. Nesse caso, o íon férrico prejudica a recuperação do níquel e do cobalto, uma vez que em trocas iônicas esse metal compete na ocupação dos sítios catiônicos. Em processos de extração por solvente um efeito semelhante é observado. Além disso, durante a eventual precipitação do ferro ocorre a coprecipitação. Assim, para a troca iônica, o íon ferroso pode ser menos prejudicial do que o férrico. O presente trabalho teve por objetivo o estudo do processo de redução do íon férrico em solução aquosa, e também a posterior obtenção de cobalto e níquel por meio de resinas quelantes. Estudou-se o processo de redução do íon férrico e o efeito na adsorção de metais por troca iônica. Os ensaios de redução química do íon férrico em solução foram estudados utilizando ditionito de sódio, metabissulfito de sódio e sulfito de sódio. Os ensaios com os agentes redutores ditionito e metabissulfito de sódio foram feitos em São Paulo, e os ensaios com o sulfito de sódio foram feitos na The University of British Columbia. Os agentes redutores foram adicionados na solução monoelementar de ferro para redução do potencial redox. As variáveis potencial redox, entre 860mV e 240mV; pH, entre 0,5 e 3,5; temperatura, entre 25°C e 60°C; e tempo, entre 30min e 96 horas, foram estudadas em frascos erlenmeyer sob agitação constante. Analisou-se, então, a redução do íon férrico em solução multielementar de níquel laterítico. Nos ensaios de troca iônica, realizados em batelada e em coluna, utilizou-se a resina quelante Lewatit TP 207, de grupo funcional iminodiacetato, e a resina Lewatit TP220, de grupo funcional bis-picolilamina. Três soluções foram estudadas: uma preparada com Fe(III), outra com Fe(II) e a terceira com Fe(III) após o processo de pré-redução. Os ensaios em batelada foram realizados com a utilização de frascos erlenmeyer, sob agitação constante, com 100mL de solução para 1mL de resina. Estudou-se o efeito do pH, entre 0,5 e 3,5; tempo, entre 30min e 480min; e temperatura, entre 25°C e 60°C. Nos ensaios em sistema contínuo, as três soluções foram alimentadas em colunas de vidro preenchidas com resina. A solução foi alimentada com bombas peristálticas a vazão constante. Para eluição das colunas, ácido sulfúrico 1mol.L-1 foi alimentado na coluna com utilização de bomba peristáltica. A segunda parte do trabalho, realizado na The University of British Columbia, foi o estudo do uso de sulfito de sódio no processo de pré-redução. Foram estudadas duas resinas: a Lewatit TP 207, seletiva para cobre; e a Lewatit TP 220, seletiva para níquel e cobalto. O sulfito de sódio foi adicionado na solução para redução do potencial, em frascos, e colocado sob agitação constante. Após reação, as soluções foram colocadas em contato com a resina quelante, e ficaram em agitação. Os ensaios em batelada foram realizados e o efeito do pH estudado entre 0,5 e 3,5. No processo em coluna, a Coluna 1, preenchida com a resina Lewatit TP 207, foi utilizada para remoção do cobre; e a solução de saída foi alimentada na Coluna 2, preenchida com a resina Lewatit TP 220. Para a eluição, foram estudados os ácidos clorídricos e sulfúricos em duas diferentes concentrações, 1mol.L-1 e 2mol.L-1. Hidróxido de sódio foi utilizado para remover o ferro na solução obtida na saída da Coluna 2. A separação do cobalto da solução foi feita utilizando a técnica de extração por solventes (Cyanex 272 20%), estudando o efeito do pH, 4,0 e 5,0, e da temperatura, 25°C e 65°C. Os resultados mostraram que a redução do íon férrico utilizando ditionito de sódio foi de 100% na solução monoelementar e de 70% na multielementar contendo os outros metais. Nos ensaios de troca iônica em batelada, utilizando a resina TP 207, 62% do cobre foi adsorvido na solução após processo de pré-redução. Para solução com Fe(II), a adsorção de cobre foi de 61%; e para solução com Fe(III), 49%. Nos ensaios de troca iônica após pré-redução do ferro com sulfito de sódio, a adsorção do cobre foi de 69% em pH 2,0 pela resina TP 207. A resina TP 220 foi mais seletiva para níquel e cobalto em pH 2,0, em que as adsorções destes metais foram 32,5% e 69%, respectivamente. Nos ensaios em coluna, a Coluna 1 foi utilizada para remoção de cobre, porém houve perda de 17% de níquel e 7% de cobalto. Na alimentação da Coluna 2, verificou-se que 98% do níquel e 84% do cobalto foram adsorvidos. A solução obtida da Coluna 2 teve concentração de 618mg.L-1 de ferro, 13231mg.L-1 de níquel e 179mg.L-1 de cobalto. A remoção de 100% do ferro foi possível em pH 4,0. Para separação do cobalto da solução rica em níquel, utilizou-se a extração por solventes com o Cyanex 272 20% em querosene, no qual 99% do cobalto foi separado da solução a 65°C e pH 5,0, sem perda de níquel. Para estudos futuros, a remoção do cobre no início do processo pode ser explorada com a utilização de outras técnicas, a fim de se evitarem perdas de níquel e cobalto. Outro ponto que pode vir a ser explorado é a máxima utilização das colunas de troca iônica nas mesmas condições deste trabalho - solução com Fe(III), com Fe(II) e após processo de pré-redução - sobretudo em escala piloto, para estudar o efeito do estado de oxidação do ferro em um possível envenenamento da resina. / Nickel laterite ores represent 70% of the available metal reserves. The nickel production from these reserves represents 40%, where it is also possible extract copper and cobalt. It occurs due to the high impurities content, mainly iron. With the growing demand of these metals, the use of nickel laterite reserves became more deeply investigated, as well as hydrometallurgical process development. In this case, the ferric iron difficult the nickel and cobalt recovery, once in ion exchange processes this metal competes in the occupation of the cationic sites. In solvent extraction processes the same effect is observed. Besides that, during the eventual iron precipitation there is a co-precipitation. Therefore, for ion exchange, ferrous iron may be less damaging than ferric iron. The aim of this work was to study the reducing process of ferric iron in aqueous solution, and also the subsequent obtaining of cobalt and nickel through chelating resins. It was studied the reducing process of ferric iron and the effect of it in metals adsorption by ion exchange. Experiments of chemical reduction of ferric iron in solution were studied using sodium dithionite, sodium metabisulfite and sodium sulfite. Experiments with reducing agents sodium dithionite and metabisulfite were performed in São Paulo, and experiments with sodium sulfite were performed in The University of British Columbia. Reducing agents were added in ferric iron mono-elementary solution to decrease the redox potential. The variables potential redox, between 860mV and 240mV; pH, between 0,5 and 3,5; temperature, between 25°C e 60°C; and time, between 30min and 96 hours were studied in erlenmeyer flasks under constant stirring. Then, analyzed ferric iron reduction in multielementary solution of nickel laterite. In ion exchange experiments, performed in batch and column, it was used chelating resin Lewatit TP 207, with iminodiacetate functional group, and resin Lewatit TP 220, with bis-picolylamine functional group. Three solutions were studied: prepared with Fe(III), other with Fe(III) and the third with Fe(III) after pre-reducing process. Experiments in batch system were performed using erlenmeyer flasks, under constant stirring, with 100mL of solution to 1mL of resin. It was studied the effect of pH, between 0,5 and 3,5, time, between 30min and 480min, and temperature, between 25°C e 60°C. In experiments in continuous system, the three solutions were fed in glass columns filled with resin. The solution was fed using peristaltic pumps at constant flow rate. For column elution, sulfuric acid 1mol.L-1 was fed to the column using peristaltic pumps. The second part of this work, performed at The University of British Columbia, was the study of sodium sulfite application at prereducing process. It was studied two resins: Lewatit TP 207, selective for copper, and Lewatit TP 220, selective for nickel and cobalt. Sodium sulfite was added to the solution to decrease the potential, in flasks and it was placed under constant stirring. After reaction, the solution was placed in contact to the chelating resin, which was placed under stirring. Batch experiments were performed, and the effect of pH was studied between 0,5 and 3,5. In column process, the Column 1, filled with Lewatit TP 207, was used for copper removal, and output solution was feed in Column 2, filled with Lewatit TP 220. For the elution, it was studied sulfuric and hydrochloric acids in two different concentrations, 1mol.L-1 e 2mol.L-1. Sodium hydroxide was used for iron removal from solution obtained in Column 2 output. Cobalt separation was performed using solvent extraction technique (Cyanex 272 20%), studying the effect of pH, 4,0 and 5,0, and temperature, 25°C e 65°C. Results shows that ferric iron reduction using sodium dithionite was 100% in mono-elementary solution and 70% in multi-elementary solution with other metals. In ion exchange experiments performed in batch using resin TP 207, 62% of copper was adsorbed by the resin after pre-reducing process. For solution with Fe(II), the copper adsorption was 61%, and for solution with Fe(III), 49%. In ion exchange experiments after pre-reducing process using sodium sulfite, the copper adsorption was 69% at pH 2,0 by the resin TP 207. The resin TP 220 was more selective for nickel and cobalt at pH 2,0, where these metals adsorptions were 32,5% and 69%, respectively. In experiments performed in column, the Column 1 was used for copper removal, however there were losses of nickel (17%) and cobalt (7%). In the feeding of Column 2, it was found that 98% of nickel and 84% of cobalt were adsorbed. Solution obtained in Column 2 had concentration of iron 618mg.L-1, nickel was 13231mg.L-1 and cobalt 179mg.L-1. The iron removal was 100% at pH 4,0. For cobalt separation in nickel-rich solution, it was used the solvent extraction with Cyanex 272 20% with kerosene, where 99% of cobalt was separated from solution at 65°C and pH 5,0, without nickel loss. For future studies, the copper removal in the beginning of the process can be explored using other techniques, in order to avoid nickel and cobalt losses. Another point that can be explored is the maximum use of ion exchange columns in the same conditions of this work - solution with Fe(III), with Fe(II) and after the pre-reducing process - mostly on a pilot scale, to study the effect of iron oxidation state on possible resin poisoning.

Níquel laterítico compõe 70% das reservas disponíveis do metal. A produção de níquel a partir dessas reservas representa 40%, dos quais é possível extrair também cobre e cobalto. Isso ocorre devido ao alto teor de impurezas, principalmente ferro. Com a crescente demanda desses metais, o uso das reservas de lateritas de níquel passou a ser mais profundamente investigado, assim como o desenvolvimento de processos hidrometalúrgicos. Nesse caso, o íon férrico prejudica a recuperação do níquel e do cobalto, uma vez que em trocas iônicas esse metal compete na ocupação dos sítios catiônicos. Em processos de extração por solvente um efeito semelhante é observado. Além disso, durante a eventual precipitação do ferro ocorre a coprecipitação. Assim, para a troca iônica, o íon ferroso pode ser menos prejudicial do que o férrico. O presente trabalho teve por objetivo o estudo do processo de redução do íon férrico em solução aquosa, e também a posterior obtenção de cobalto e níquel por meio de resinas quelantes. Estudou-se o processo de redução do íon férrico e o efeito na adsorção de metais por troca iônica. Os ensaios de redução química do íon férrico em solução foram estudados utilizando ditionito de sódio, metabissulfito de sódio e sulfito de sódio. Os ensaios com os agentes redutores ditionito e metabissulfito de sódio foram feitos em São Paulo, e os ensaios com o sulfito de sódio foram feitos na The University of British Columbia. Os agentes redutores foram adicionados na solução monoelementar de ferro para redução do potencial redox. As variáveis potencial redox, entre 860mV e 240mV; pH, entre 0,5 e 3,5; temperatura, entre 25°C e 60°C; e tempo, entre 30min e 96 horas, foram estudadas em frascos erlenmeyer sob agitação constante. Analisou-se, então, a redução do íon férrico em solução multielementar de níquel laterítico. Nos ensaios de troca iônica, realizados em batelada e em coluna, utilizou-se a resina quelante Lewatit TP 207, de grupo funcional iminodiacetato, e a resina Lewatit TP220, de grupo funcional bis-picolilamina. Três soluções foram estudadas: uma preparada com Fe(III), outra com Fe(II) e a terceira com Fe(III) após o processo de pré-redução. Os ensaios em batelada foram realizados com a utilização de frascos erlenmeyer, sob agitação constante, com 100mL de solução para 1mL de resina. Estudou-se o efeito do pH, entre 0,5 e 3,5; tempo, entre 30min e 480min; e temperatura, entre 25°C e 60°C. Nos ensaios em sistema contínuo, as três soluções foram alimentadas em colunas de vidro preenchidas com resina. A solução foi alimentada com bombas peristálticas a vazão constante. Para eluição das colunas, ácido sulfúrico 1mol.L-1 foi alimentado na coluna com utilização de bomba peristáltica. A segunda parte do trabalho, realizado na The University of British Columbia, foi o estudo do uso de sulfito de sódio no processo de pré-redução. Foram estudadas duas resinas: a Lewatit TP 207, seletiva para cobre; e a Lewatit TP 220, seletiva para níquel e cobalto. O sulfito de sódio foi adicionado na solução para redução do potencial, em frascos, e colocado sob agitação constante. Após reação, as soluções foram colocadas em contato com a resina quelante, e ficaram em agitação. Os ensaios em batelada foram realizados e o efeito do pH estudado entre 0,5 e 3,5. No processo em coluna, a Coluna 1, preenchida com a resina Lewatit TP 207, foi utilizada para remoção do cobre; e a solução de saída foi alimentada na Coluna 2, preenchida com a resina Lewatit TP 220. Para a eluição, foram estudados os ácidos clorídricos e sulfúricos em duas diferentes concentrações, 1mol.L-1 e 2mol.L-1. Hidróxido de sódio foi utilizado para remover o ferro na solução obtida na saída da Coluna 2. A separação do cobalto da solução foi feita utilizando a técnica de extração por solventes (Cyanex 272 20%), estudando o efeito do pH, 4,0 e 5,0, e da temperatura, 25°C e 65°C. Os resultados mostraram que a redução do íon férrico utilizando ditionito de sódio foi de 100% na solução monoelementar e de 70% na multielementar contendo os outros metais. Nos ensaios de troca iônica em batelada, utilizando a resina TP 207, 62% do cobre foi adsorvido na solução após processo de pré-redução. Para solução com Fe(II), a adsorção de cobre foi de 61%; e para solução com Fe(III), 49%. Nos ensaios de troca iônica após pré-redução do ferro com sulfito de sódio, a adsorção do cobre foi de 69% em pH 2,0 pela resina TP 207. A resina TP 220 foi mais seletiva para níquel e cobalto em pH 2,0, em que as adsorções destes metais foram 32,5% e 69%, respectivamente. Nos ensaios em coluna, a Coluna 1 foi utilizada para remoção de cobre, porém houve perda de 17% de níquel e 7% de cobalto. Na alimentação da Coluna 2, verificou-se que 98% do níquel e 84% do cobalto foram adsorvidos. A solução obtida da Coluna 2 teve concentração de 618mg.L-1 de ferro, 13231mg.L-1 de níquel e 179mg.L-1 de cobalto. A remoção de 100% do ferro foi possível em pH 4,0. Para separação do cobalto da solução rica em níquel, utilizou-se a extração por solventes com o Cyanex 272 20% em querosene, no qual 99% do cobalto foi separado da solução a 65°C e pH 5,0, sem perda de níquel. Para estudos futuros, a remoção do cobre no início do processo pode ser explorada com a utilização de outras técnicas, a fim de se evitarem perdas de níquel e cobalto. Outro ponto que pode vir a ser explorado é a máxima utilização das colunas de troca iônica nas mesmas condições deste trabalho - solução com Fe(III), com Fe(II) e após processo de pré-redução - sobretudo em escala piloto, para estudar o efeito do estado de oxidação do ferro em um possível envenenamento da resina. / Nickel laterite ores represent 70% of the available metal reserves. The nickel production from these reserves represents 40%, where it is also possible extract copper and cobalt. It occurs due to the high impurities content, mainly iron. With the growing demand of these metals, the use of nickel laterite reserves became more deeply investigated, as well as hydrometallurgical process development. In this case, the ferric iron difficult the nickel and cobalt recovery, once in ion exchange processes this metal competes in the occupation of the cationic sites. In solvent extraction processes the same effect is observed. Besides that, during the eventual iron precipitation there is a co-precipitation. Therefore, for ion exchange, ferrous iron may be less damaging than ferric iron. The aim of this work was to study the reducing process of ferric iron in aqueous solution, and also the subsequent obtaining of cobalt and nickel through chelating resins. It was studied the reducing process of ferric iron and the effect of it in metals adsorption by ion exchange. Experiments of chemical reduction of ferric iron in solution were studied using sodium dithionite, sodium metabisulfite and sodium sulfite. Experiments with reducing agents sodium dithionite and metabisulfite were performed in São Paulo, and experiments with sodium sulfite were performed in The University of British Columbia. Reducing agents were added in ferric iron mono-elementary solution to decrease the redox potential. The variables potential redox, between 860mV and 240mV; pH, between 0,5 and 3,5; temperature, between 25°C e 60°C; and time, between 30min and 96 hours were studied in erlenmeyer flasks under constant stirring. Then, analyzed ferric iron reduction in multielementary solution of nickel laterite. In ion exchange experiments, performed in batch and column, it was used chelating resin Lewatit TP 207, with iminodiacetate functional group, and resin Lewatit TP 220, with bis-picolylamine functional group. Three solutions were studied: prepared with Fe(III), other with Fe(III) and the third with Fe(III) after pre-reducing process. Experiments in batch system were performed using erlenmeyer flasks, under constant stirring, with 100mL of solution to 1mL of resin. It was studied the effect of pH, between 0,5 and 3,5, time, between 30min and 480min, and temperature, between 25°C e 60°C. In experiments in continuous system, the three solutions were fed in glass columns filled with resin. The solution was fed using peristaltic pumps at constant flow rate. For column elution, sulfuric acid 1mol.L-1 was fed to the column using peristaltic pumps. The second part of this work, performed at The University of British Columbia, was the study of sodium sulfite application at prereducing process. It was studied two resins: Lewatit TP 207, selective for copper, and Lewatit TP 220, selective for nickel and cobalt. Sodium sulfite was added to the solution to decrease the potential, in flasks and it was placed under constant stirring. After reaction, the solution was placed in contact to the chelating resin, which was placed under stirring. Batch experiments were performed, and the effect of pH was studied between 0,5 and 3,5. In column process, the Column 1, filled with Lewatit TP 207, was used for copper removal, and output solution was feed in Column 2, filled with Lewatit TP 220. For the elution, it was studied sulfuric and hydrochloric acids in two different concentrations, 1mol.L-1 e 2mol.L-1. Sodium hydroxide was used for iron removal from solution obtained in Column 2 output. Cobalt separation was performed using solvent extraction technique (Cyanex 272 20%), studying the effect of pH, 4,0 and 5,0, and temperature, 25°C e 65°C. Results shows that ferric iron reduction using sodium dithionite was 100% in mono-elementary solution and 70% in multi-elementary solution with other metals. In ion exchange experiments performed in batch using resin TP 207, 62% of copper was adsorbed by the resin after pre-reducing process. For solution with Fe(II), the copper adsorption was 61%, and for solution with Fe(III), 49%. In ion exchange experiments after pre-reducing process using sodium sulfite, the copper adsorption was 69% at pH 2,0 by the resin TP 207. The resin TP 220 was more selective for nickel and cobalt at pH 2,0, where these metals adsorptions were 32,5% and 69%, respectively. In experiments performed in column, the Column 1 was used for copper removal, however there were losses of nickel (17%) and cobalt (7%). In the feeding of Column 2, it was found that 98% of nickel and 84% of cobalt were adsorbed. Solution obtained in Column 2 had concentration of iron 618mg.L-1, nickel was 13231mg.L-1 and cobalt 179mg.L-1. The iron removal was 100% at pH 4,0. For cobalt separation in nickel-rich solution, it was used the solvent extraction with Cyanex 272 20% with kerosene, where 99% of cobalt was separated from solution at 65°C and pH 5,0, without nickel loss. For future studies, the copper removal in the beginning of the process can be explored using other techniques, in order to avoid nickel and cobalt losses. Another point that can be explored is the maximum use of ion exchange columns in the same conditions of this work - solution with Fe(III), with Fe(II) and after the pre-reducing process - mostly on a pilot scale, to study the effect of iron oxidation state on possible resin poisoning.

Le gisement nickélifère latéritique de Nouvelle-Calédonie, développé au toit de la Nappe des Péridotites, représente près de 20% des ressources mondiales en nickel. Afin de mieux comprendre la formation de ce gisement, notre étude, portant sur le massif de Koniambo, se singularise par la volonté de ne pas se focaliser uniquement sur la zone minéralisée. L’approche employée a combiné : i) l’analyse de la déformation interne de l’ensemble du massif, ii) la caractérisation isotopique de deux sous-produits supposés de l’altération supergène que ont les veines de quartz et les veines de magnésite, iii) la modélisation 3D du gisement nickélifère, basée sur les données de plus de 6000 forages de subsurface et sur l’étude d’affleurements ponctuels au sein de la zone minéralisée. L’évolution spatiale et temporelle de la déformation associée à la serpentinisation est décrite au travers des ~800 m d’épaisseur structurale du massif de Koniambo. La partie supérieure du massif, très fracturée, préserve la marque d’au moins deux événements précoces de déformation. Le premier est associé au réseau de failles à antigorite et le second au réseau de failles à serpentine polygonale. La semelle serpentineuse, épaisse de ~200 m, est constituée de brèches et mylonites et enregistre un cisaillement tangentiel diffus associé à la serpentine polygonale et à la magnésite. La semelle représente ainsi un niveau de décollement majeur en base de nappe. Entre la semelle et le haut du massif, un niveau intermédiaire est identifié, caractérisé par la présence de zones de cisaillement plurimétriques probablement connectées à la semelle. La caractérisation 3D de la distribution du nickelau sein du niveau saprolitique, à l’échelle du gisement comme à l’échelle de l’affleurement, permetde mettre en évidence l’existence de processus impliquant une redistribution non pas seulement verticale, comme il est classiquement admis, mais aussi latérale, mécanique ou associée à des fluides, à l’origine d’importants enrichissements locaux. L’analyse isotopique des veines de quartz associées au minerai garniéritique met en évidence les conditions d’hydrothermalisme de basse température associées à leur formation. La caractérisation structurale et isotopique (couplage ''isotopes stables'' et ''clumped isotope thermometry'') des veines de magnésite situées dans la semelle serpentineuse permet de documenter leur caractère syn-tectonique et la nature météorique et de basse température du fluide dont elles sont issues. Ceci nous amène à proposer que la tectonique active a pu faciliter l’infiltration de l’eau météorique impliquée dans le processus de latérisation depuis le sommet jusqu’à la base de la nappe. / The New Caledonia nickel laterite ore deposit, developed at the top of the Peridotite Nappe, hosts about 20% of the nickel resources worldwide. In order to better understand the formation of this eposit, our study, focusing on the Koniambo Massif, is not restricted to the ore zone but concerned with the whole peridotite pile. Our approach combined: i) the analysis of the internal deformation of the massif, ii) the isotopic characterization of quartz and magnesite veins which are suspected to represent by-products of the laterization process, iii) the 3D modelling of the lateritenickel ore deposit, based on a dataset of ~6000 subsurface boreholes and the study of some outcrops located into the mineralized area. The spatial and temporal evolution of the deformation associated with serpentinization is described across the ~800 m-thick rock pile of the Koniambo Massif. The upper part of the massif is densely faulted and preserves the record of two early deformation events. The first one is associated with synantigorite faults and the second one with syn-polygonal serpentine faults. The ~200m-thick serpentine sole is composed of breccias and mylonites and records pervasive tangential shearing associated with polygonal serpentine and magnesite. Thus, the serpentine sole represents a major décollement at the base of the nappe. Between the sole and the upper part of the massif, anintermediate structural level is identified, characterized by the presence of plurimetric shear zones that probably merge with the sole.The 3D characterization of the nickel distribution in the saprolite level, at both deposit and outcrop scales, gives evidence for processes implying not only vertical (as commonly assumed) but also lateral nickel redistribution. This lateral transport ismechanical or associated with fluids and leads to significant local enrichments. The isotopic characterization of the quartz veins associated with garnieritic ore shows that they formed under low temperature hydrothermal conditions. The structural and isotopic (coupling “stable isotope” and “clumped isotope thermometry”) characterization of the magnesite veins located at the serpentine sole shows that they are syn-tectonic and derived from low temperature meteoric water. As a result, we propose that active tectonics has enhanced the infiltration of the meteoric waters involved in the laterization process down to the base of the nappe.