The Optimum Path To Battery ChemicalsTraditional ways of making battery chemicals include:
1. Sulfide ore --> concentration --> smelting --> purification --> dissolve in acid --> battery chemicals
2. Limonite ore --> dissolve in acid --> purification --> battery chemicals
A big problem with laterite ores, both limonite and saprolite, is the lack of any viable methods of concentration. A high temperature roast has been proposed, converting the nickel into awaruite to permit magnetic concentration prior to HPAL, but the roasting temperature is so high that the energy expended is almost the same as needed for RKEF NPI.
Several other options for battery chemicals are being implemented or considered:
1.) Laterite ore --> RKEF --> Matte Converter --> dissolve in acid --> purification --> battery chemicals (Suggested by RNC, likely being developed by Tsingshan)
2.) Sulfide ore --> Sulfation roasting to create solid NiSO4--> dissolve in water --> purification --> battery chemicals (Suggested by RNC, currently being tested)
3.) Awaruite ore --> concentration --> dissolve in acid --> purification --> battery chemicals (Currently an option for both FPX Nickel at Baptiste and RNC Nickel at Dumont)
The first 2 options use both pyrometallurgy and hydrometallurgy, where awaruite ores require only hydrometallurgy and should therefore enjoy a cost advantage.
Another thing to consider is the quality of the awaruite concentrate. While FPX Baptiste concentrate is presently higher grade (55-72% nickel compared to 30-50% nickel at RNC Dumont), RNC Dumont should be able to achieve the same high grade by reducing their grind size from the current 45 microns to the same 25 microns specified in the FPX flowsheet.
The higher the concentrate grade, the smaller the size of the leech plant and the less CAPEX required.
The amenability of awaruite nickel ores to magnetic concentration must be viewed as a significant competitive advantage in the race for technological advancement for the production of battery chemicals. And it is remains entirely possible for FPX and RNC to emerge as winners against Tsingshan in the competition for low cost mine-to-battery chemicals.