An attempt into identification of suitable recovery process for nickel value from nickel sulfide ore and tailings

M.Tech (Metallurgy)Nickel in South Africa is scarce. Other than as a by-product from platinum mining, its only source is the Uitkomst Complex, a satelite of the Bushveld Igneous Complex, located between Machadodorp and Barberton and mined by Nkomati Nickel. Pentlandite occurs as the main nickel-bearing mineral, disseminated within a sulfide matrix of pyrrhotite, pyrite and chalcopyrite. Accessories are of chromite and platinum in solid solution with the sulfides. The sulfides are hosted in mainly ultramafic rocks. The presence of talc is of particular nuisance. Head grade is in the decline, from earlier 0.7 to more recently 0.3% or even lower. Standard froth flotation yields a concentrate of 7 – 9% nickel at a recovery of up to 70%. A higher nickel recovery from such low – grade feed stock would be desirable. To achieve these two methods were investigated and reported in the following:  Non-oxidative leaching as an alternative to flotation, using strong hydrochloric and sulfuric acid and also aqueous ammonia solutions at various liquid-to-solid ratios. Only the degree of nickel dissolution over time at room temperature was studied and no attempt was made to recover the dissolved metal from solution.  Froth flotation after pre-treatment with microwaves at various power levels and over various periods of time of irradiation. It was surmised that a certain amount of inter-granular cracking could thus be achieved that would improve the flotation behavior in respect of grade and recovery. An extensive literature study, in particular, of the nature of microwaves, their interaction with matter and possible metallurgical benefits derived as a consequence of such interaction, forms part of the investigation and is reported in detail. A lot of theoretical and experimental work has been done in this respect, although the obtained results were not conclusive