Process flow:
This equipment is used to receive the hot melt waste slag from the
vulcanization furnace, and the waste slag is depleted.
Raw materials such as hot calcine and dry nickel and cobalt sulfide
are added to the vulcanization furnace and melted by electric
heating. After a certain period of time, the liquid nickel and
cobalt matte flows through the iron outlet through the chute into
the ladle, and the ladle is moved to the LF refining position under
the ladle truck to begin refining. The slag from the slag mouth of
the vulcanized furnace is buffered by the chute and flows directly
into the dilution furnace of the downstream process.
Manufacturing method and process of high purity nickel sulfate:
Process description:
The nickel cobalt matte produced by the vulcanized electric furnace
flows through the chute into the ladle, and the ladle moves to the
LF refining position under the ladle car, and begins refining.
The annual output of 30,000 tons of high-purity ternary power
battery grade nickel sulfate project is a key part of the new
energy industry chain, aiming to provide high-quality nickel
sulfate raw materials for ternary lithium-ion batteries. The
pretreatment equipment is the first crucial link in the project,
responsible for efficiently and environmentally friendly handling
of nickel-containing raw materials (such as nickel concentrate,
nickel oxide ore, or recycled battery materials), removing
impurities, and adjusting the material properties to meet the
requirements of subsequent leaching, purification, and
crystallization processes. Its stable operation and processing
efficiency directly affect the overall project's product quality,
production cost, and environmental performance.
- Equipment Configuration: Jaw crusher, cone crusher, ball mill, classifier.
- Function: First, the large-sized nickel-containing raw materials are
crushed into small particles by the jaw crusher and cone crusher,
and then ground into fine powder by the ball mill to increase the
specific surface area of the material, which is conducive to the
full reaction in the subsequent leaching process. The classifier
controls the particle size of the ground powder to ensure that the
material entering the next process meets the specified fineness
requirements (usually 200-325 mesh).
- Advantages: Adopts advanced crushing and grinding technology, with high
crushing ratio, uniform product particle size, and low energy
consumption. The closed-circuit grinding system formed by the ball
mill and classifier improves the grinding efficiency and reduces
the loss of raw materials.
- Equipment Configuration: Magnetic separator, shaking table, spiral concentrator.
- Function: For nickel-containing raw materials with magnetic properties
(such as nickel-iron ore), the magnetic separator is used to
separate the magnetic nickel minerals from the gangue minerals; for
raw materials with different densities, the shaking table or spiral
concentrator is used to separate the nickel minerals from the
gangue based on the density difference, thereby increasing the
nickel grade of the material and reducing the processing load of
subsequent processes.
- Advantages: The magnetic separation equipment has high magnetic field
strength, good separation effect, and can effectively recover
magnetic nickel minerals; the gravity separation equipment has
simple structure, reliable operation, and low operating cost, and
can effectively separate non-magnetic nickel minerals.
- Equipment Configuration: Rotary kiln, fluidized bed roaster.
- Function: For some nickel-containing raw materials that are difficult to
leach (such as nickel sulfide concentrate), roasting is required to
convert the nickel sulfide into nickel oxide, which is easier to
leach. During the roasting process, sulfur dioxide gas is
generated, which can be recycled to produce sulfuric acid,
realizing the comprehensive utilization of resources.
- Advantages: The rotary kiln has large processing capacity, uniform roasting
temperature, and good adaptability to raw materials; the fluidized
bed roaster has high roasting efficiency, good gas-solid contact,
and can realize continuous production.
- Equipment Configuration: Stirred tank leacher, pressure leacher.
- Function: The pretreated nickel-containing materials are mixed with
leaching agents (such as sulfuric acid) in the leacher, and under
certain temperature, pressure, and stirring conditions, the nickel
in the materials is leached into the solution to form nickel
sulfate solution. The leaching equipment is designed to ensure
sufficient contact between the material and the leaching agent,
improve the leaching rate of nickel.
- Advantages: The stirred tank leacher has simple structure, easy operation,
and can handle a wide range of materials; the pressure leacher can
improve the leaching rate and leaching efficiency under high
temperature and high pressure conditions, especially suitable for
leaching difficult-to-leach nickel raw materials.
- Equipment Configuration: Plate and frame filter press, vacuum filter, washing tower.
- Function: After leaching, the nickel sulfate solution contains a large
amount of solid impurities (such as gangue, unreacted minerals).
The filter press or vacuum filter is used to separate the solid
impurities from the solution to obtain a clear nickel sulfate
solution. The washing tower is used to wash the filter residue to
recover the nickel sulfate adhering to the filter residue, reducing
the loss of nickel.
- Advantages: The plate and frame filter press has high filtration pressure,
good filtration effect, and can handle large amounts of slurry; the
vacuum filter has high filtration speed, continuous operation, and
low labor intensity; the washing tower has high washing efficiency,
which can effectively recover the nickel sulfate in the filter
residue.
- Equipment Configuration: Neutralization tank, precipitation tank, ion exchange column.
- Function: The nickel sulfate solution obtained after filtration still
contains a small amount of impurities (such as iron, aluminum,
copper, zinc, etc.), which will affect the quality of the final
nickel sulfate product. The neutralization tank is used to adjust
the pH value of the solution to precipitate iron and aluminum; the
precipitation tank is used to add precipitants to precipitate
copper, zinc, and other impurities; the ion exchange column is used
to further remove trace impurities in the solution to obtain a
high-purity nickel sulfate solution.
- Advantages: The impurity removal process is designed reasonably, and the
combination of multiple impurity removal methods ensures the
removal effect of impurities; the ion exchange column has high
adsorption capacity and selectivity, and can effectively remove
trace impurities.
The pretreatment equipment adopts advanced technology and
equipment, with reasonable process layout and high degree of
automation, which can realize continuous and large-scale
production, and the annual processing capacity of raw materials can
reach more than 30,000 tons, meeting the requirements of the
project's annual output of 30,000 tons of high-purity nickel
sulfate.
The equipment can effectively remove impurities in the raw
materials, adjust the material properties, and ensure that the
nickel sulfate solution entering the subsequent purification and
crystallization processes has high purity, which lays a solid
foundation for producing high-purity ternary power battery grade
nickel sulfate products.
The equipment adopts energy-saving technologies and equipment, such
as high-efficiency motors, frequency conversion speed regulation,
etc., to reduce energy consumption; at the same time, it is
equipped with complete environmental protection facilities, such as
dust removal, desulfurization, and wastewater treatment equipment,
to ensure that the waste gas, wastewater, and solid waste generated
during the production process meet the national environmental
protection standards, realizing green production.
The pretreatment equipment can handle a variety of
nickel-containing raw materials, such as nickel concentrate, nickel
oxide ore, recycled battery materials, etc., and can adjust the
process parameters according to the properties of different raw
materials to ensure the stability and reliability of the production
process.
The equipment is equipped with an advanced automatic control
system, which can realize real-time monitoring and automatic
adjustment of the production process parameters, improving the
stability and reliability of the production process; at the same
time, it is equipped with a complete fault diagnosis and alarm
system, which is convenient for operators to find and solve
problems in time, reducing the maintenance cost and downtime.
The pretreatment equipment for the 30,000 tons/year high-purity
ternary power battery grade nickel sulfate project is a key part of
the project, which undertakes the important tasks of raw material
processing, impurity removal, and material property adjustment. The
equipment has the advantages of high processing efficiency, good
product quality, energy conservation and environmental protection,
strong adaptability, and intelligent operation and maintenance,
which can provide strong support for the smooth operation of the
project and the production of high-quality nickel sulfate products.
In the future, with the continuous development of the new energy
industry, the demand for high-purity nickel sulfate will continue
to grow, and the pretreatment equipment will play an increasingly
important role in the nickel sulfate production process.
