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    US20150225810A1 - Iron Recovery Method 2015

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    Eduardo Candela
    The document discloses an iron recovery method from a leach solution obtained from leaching a nickel laterite ore. The method involves oxidizing and hydrolyzing a ferric sulfate and urea mix solution at 60-100°C to precipitate iron in the form of hematite. Nickel and cobalt can be recovered from the solution prior to iron recovery using resins or other methods. The recovered iron oxide, hematite, is a usable product while acid and urea are recycled.

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    US20150225810A1 - Iron Recovery Method 2015

    Uploaded by

    Eduardo Candela
    9 views3 pages
    The document discloses an iron recovery method from a leach solution obtained from leaching a nickel laterite ore. The method involves oxidizing and hydrolyzing a ferric sulfate and urea mix solution at 60-100°C to precipitate iron in the form of hematite. Nickel and cobalt can be recovered from the solution prior to iron recovery using resins or other methods. The recovered iron oxide, hematite, is a usable product while acid and urea are recycled.

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    US20150225810A1 - Iron recovery method 2015

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    The document discloses an iron recovery method from a leach solution obtained from leaching a nickel laterite ore. The method involves oxidizing and hydrolyzing a ferric sulfate and urea mix solution at 60-100°C to precipitate iron in the form of hematite. Nickel and cobalt can be recovered from the solution prior to iron recovery using resins or other methods. The recovered iron oxide, hematite, is a usable product while acid and urea are recycled.

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    © All Rights Reserved
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    Flag for inappropriate content
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    9 views3 pages

    US20150225810A1 - Iron Recovery Method 2015

    Uploaded by

    Eduardo Candela
    The document discloses an iron recovery method from a leach solution obtained from leaching a nickel laterite ore. The method involves oxidizing and hydrolyzing a ferric sulfate and urea mix solution at 60-100°C to precipitate iron in the form of hematite. Nickel and cobalt can be recovered from the solution prior to iron recovery using resins or other methods. The recovered iron oxide, hematite, is a usable product while acid and urea are recycled.

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    US 20150225810A1

    (19) United States


    (12) Patent Application Publication (10) Pub. No.: US 2015/0225810 A1
    Canbekte (43) Pub. Date: Aug. 13, 2015
    (54) IRON RECOVERY METHOD Publication Classification
    (71) Applicant: Husnu Sinan Canbekte, Istanbul (TR) (51) Int. Cl.
    C22B3/44 2006.O1
    (72) Inventor: Zekeriya Canbekte, Istanbul (TR) COIG 49/06 :08:
    (73) Assignee: Husnu Sinan Canbekte, Istanbul (TR) (52) U.S. Cl.
    CPC. C22B 3/44 (2013.01); COIG 49/06 (2013.01)
    (21) Appl. No.: 14/425,922

    (86). PCT No.: PCT/EP2013/068159


    S371 (c)(1) A method for recovery of iron in the form of an iron oxide as
    (2) Date: s Mar 4, 2015 useful product, such as hematite, from a leach Solution
    9 obtained from leaching of a nickel laterite ore, is proposed
    (30) Foreign Application Priority Data which comprises an oxidation and a hydrolysis of a ferric
    Sulphate and urea mix solution Stemming from leaching of
    Sep. 4, 2012 (EP) .................................. 12182923.8 nickel laterite ores at a temperature of 60-100° C.
    US 2015/022581.0 A1 Aug. 13, 2015

    RON RECOVERY METHOD 0009. During the work leading to the present invention it
    was found possible to recover iron under atmospheric condi
    TECHNICAL FIELD OF THE INVENTION tions from a Fe2(SO4)3/urea solution containing nickel and
    cobalt Sulphates.
    0001. The present invention relates to a process for the 0010 Nickel and cobalt may be recovered from the solu
    precipitation of iron as hematite from a solution of Fe2(SO4) tion prior to iron recovery by resins or by any other available
    3/urea mixture containing nickel and cobalt Sulphates. method after iron recovery.
    0011. An advantage with the method according to the
    BACKGROUND invention is that the method can in preferred embodiments
    thereof be performed at atmospheric pressure and at tem
    0002 Leaching of nickel laterite ores with sulphuric acid peratures from 60° C. to 100°C., that no gases are emitted and
    is a widely applied process. Some recent researches indicate that, due to short residence time, simple and inexpensive
    that when urea is added to the leach solution in sufficient equipment can be used to perform the method. Furthermore,
    amounts, metal dissolution rates and metal recoveries into the iron can be recovered as a usable product and an important
    Solution markedly increase. As such, the leaching time drops part of the acid and nearly all of the urea can be recycled to be
    to one hour and metal recoveries rise above 95%. used in the leaching of fresh nickel laterite ores or nickel
    0003. These improvements are due to the effect of urea on bearing materials, which results in reduced acid consumption
    the dissolution of iron contained in the metal bearing mate in the leaching.
    rial. When iron is attacked and forced into dissolution, other 0012. Thus, the present invention relates to a process
    metals that are bound with iron in some kind of iron bond involving recovery of dissolved iron as iron oxide and recy
    become easy targets for Sulphuric acid and thus their disso cling of the leach mixture.
    lution rate increases markedly. 0013 Advantageously, sulphuric acid associated with iron
    0004 Iron removal from the leach solution is important for dissolution is recovered substantially without loss.
    the recovery of other metals and for process economics. Iron 0014 Furthermore, urea which is important in reducing
    is normally removed from the Solution as jarosite, goethite or the leaching time of nickelbearing materials and for increas
    hematite but none of them result in a usable iron product. ing the leaching recoveries of nickel and cobalt is recovered
    Jarosite and goethite produced as Such are discarded as waste virtually without any loss.
    with no economic value. For hematite production, iron pre 0015. Additional features of the method according to the
    invention will be evident from the following description and
    cipitation should be carried out in an autoclave at tempera the appended claims.
    tures of over 200° C. and oxygen pressure of 18 bars or above.
    Iron can also be precipitated out of the solution as hydroxide DETAILED DESCRIPTION OF THE INVENTION
    produced by precipitation with lime to be discarded as waste.
    0005. A great deal of research has been conducted in 0016. The term metal used herein and in the appended
    respect of iron precipitation as hematite that can be used in claims may encompass nickel, cobalt and any other metals
    industry. U.S. Pat. No. 7,294.319 describes a method for that are normally soluble in Sulphuric acid.
    precipitating iron from Zinc Sulphate Solution as hematite 0017 Not all of steps a) throughi) as detailed below must
    under atmospheric conditions. Similarly, WO 2007/079532 be realized in a method according to the invention but may be
    describes a hydrometallurgical method for precipitating iron combined freely in a particular embodiment thereof.
    in the form of hematite from leach solutions containing 0018 a) For the recovery of iron as hematite or usable iron
    nickel, cobalt and iron. oxide, the pH of the leach solution from leaching of nickel
    bearing material is adjusted to a pH of 2.5-3.0 by treating the
    0006. The Article “Uniform Particles with a large surface solution with nickel laterite ore or nickelbearing material. No
    area formed by hydrolysis of Fe2(SO4)3 with Urea pub lime or limestone is used for pH adjustment in order to pre
    lished in 1999 in Materials Research Bulletin Vol 34 No 6 pp vent loss of Sulphuric acid through formation of gypsum.
    905-919 describes hydrolysis of iron oxide from a solution of 0019 b) Following solid liquid separation, the residue
    Fe2(SO4)3/Urea mixture under various conditions. The obtained after pH adjustment is sent to a separate leach sys
    article indicates that slow hydrolysis of aqueous solutions of tem, while the solution with pH 2.5-3.0 is stirred at a tem
    Fe2(SO4)3 with Urea in the temperature range 60-100° C. perature of around 90° C. Celsius.
    leads to a characteristic form of iron (III) hydrous oxides and 0020 c) Nickel and cobalt dissolved in the leach solution
    basic sulfates. Thermal dehydration of this iron (III) hydrous may be recovered prior to iron recovery by resins or, alterna
    oxides yields amorphous Fe2O3. tively, they may be recovered after iron recovery by any
    known method such as solvent extraction and/or electrolysis.
    SUMMARY 0021 d) While stirring the solution, an oxidizing agent
    Such as hydrogen peroxide and/or oxygen/air is added.
    0007. The object of the invention is to provide a method 0022 e) Addition of ferrous sulphate in a stochiometric
    for efficient recovery of iron as a usable iron oxide product, amount helps with conversion of goethite to hematite.
    such as hematite, without losing urea from a Fe2(SO4)3/urea 0023 f) After about 20-30 minutes of stirring, hematite
    mix solution containing nickel and cobalt Sulphates resulting particles are added as seed particles. When the stirring is
    from leaching of nickel laterite ores with a mixture of sulphu stopped, flocs of iron oxide particles start to form and settle
    ric acid and urea. fast.
    0008. This object is achieved by means of a method com 002.4 g) The slurry is then filtered easily to separate iron
    prising the features of the invention. Preferred further oxides from the solution.
    embodiments of the method are defined below and in the 0025 h) The solution, which is now free of iron but con
    claims. tains nickel and/or cobalt, if those have not been recovered
    US 2015/022581.0 A1 Aug. 13, 2015

    previously, will have a pH of around 1.0-1.5 which, if nickel TABLE-continued


    and cobalt concentrations are not high enough, can be sent to
    a leaching system. Iron Product
    0026 i) Ifnickel and cobalt concentration of the solution is Parameter XRF Analyses (%) AAS Results (%)
    high enough, said solution can be treated further to recover
    metals. If any pH adjustment of the solution is required for NO O.O3
    this purpose, this can be achieved by treating the solution with CaO
    nickelbearing material. Any residue from this pH adjustment MnO O.39
    leach will be sent to a leaching system. SO3 3.33
    0027 Practically, the method is advantageously per LOI
    Fe
    7.3
    55.6
    formed in vessels made from stainless steels or mild steel or N O.018
    concrete tanks which can be lined with proper protective Co O.007
    lining.
    0028. The invention will now be further explained in the 1. A method for recovery of iron in the form of an iron oxide
    following example. This example is only intended to illustrate as useful product from a leach solution obtained from leach
    the invention and should in no way be considered to limit the ing of a nickellaterite ore, comprising oxidation and hydroly
    Scope of the invention. sis of ferric Sulphate and an urea mix solution from leaching
    0029. Example for iron precipitation of nickel laterite ores at a temperature of 60-100° C.
    0030. A leach solution obtained from leaching of a nickel 2. The method according to the claim 1, further comprising
    laterite ore was used. The pH of the process leach solution adjusting a pH of iron bearing solution to 2.5-3.0 with nickel
    (PLS) was adjusted to 2.5-3.0 with nickel laterite ore and laterite ore before iron recovery.
    hydrogen peroxide was added to the Solution which was kept 3. The method according to claim 1 further comprising
    at 90° C. for 1 hour while stirring. After addition of hematite performing the method at atmospheric pressure.
    seeding, iron was precipitated out of PLS mainly as hematite. 4. The method according to claim 1, further comprising
    After iron precipitation, acid associated with iron is released using at least one of hydrogen peroxide, air, or oxygen gas as
    back into the PLS. As a result, pH of the PLS decreased to an oxidizer.
    about 1. The iron product composition is given in the table. Ni 5. The method according to claim 1, further comprising
    content of the product is very low. using hematite seedings to initiate iron oxide formation.
    6. The method according to claim 1, wherein if after con
    TABLE version of iron to iron oxide the solution pH drops to 1.0-1.5.
    reusing the Solution for leaching of fresh nickelbearing mate
    Iron Product rial.
    Parameter XRFAnalyses (%) AAS Results (%) 7. The method according to claim 1, further comprising
    recovering Sulphuric acid associated with iron dissolution
    Fe2O3 86 substantially without loss.
    SiO2 1.63 8. The method according to claim 1, further comprising
    MgO
    Al2O3 O.31 recovering urea virtually without any loss.
    k k k k k

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