case study
Development of A Novel Process for Extraction of Nickel and Cobalt From Limonite and Saprolite Ores
Project Summary
Our consulting engineering firm was engaged by a United States-based company to support the development of an innovative leaching technology for nickel and cobalt extraction from limonitic and saprolitic ores. The scope of work included advanced process simulation, technoeconomic analysis (TEA), life cycle assessment (LCA), and support for intellectual property development. The goal was to validate the process performance, identify environmental and economic advantages over conventional technologies, and support ongoing R&D and commercialization.
Challenge
The extraction of nickel and cobalt from laterite ores traditionally relies on high pressure acid leaching (HPAL), which is capital-intensive and energy-demanding. The client aimed to develop a lower-cost, lower-impact alternative using atmospheric leaching. A rigorous comparison with HPAL was required, along with detailed modeling to evaluate water and energy efficiency, economic viability, and environmental performance. The challenge lay in simulating the complex chemistry, integrating recycling streams, and quantifying performance metrics to inform both technology development and investor engagement.
Solution
We delivered a comprehensive, data-driven solution that included:
Process Simulation:
Modeled the atmospheric leaching process to obtain accurate mass and energy balances and simulate all relevant chemical reactions and
recycle loops.
Flowsheet Development:
Designed a complete process flowsheet integrating all major unit operations and internal recycling streams to optimize resource efficiency.
Technoeconomic Analysis:
Performed detailed cost modeling and economic feasibility assessments, including capital and operating cost estimation and sensitivity analysis.
Life Cycle Assessment:
Conducted cradle-to-gate LCA to evaluate greenhouse gas emissions, water usage, and energy consumption, benchmarking against HPAL.
Comparative Evaluation:
Simulated HPAL in parallel, enabling direct comparison of performance, cost, and environmental impact.
Technology and Patent Development:
Supported the client with technical documentation and modeling insights required for patent drafting and ongoing R&D.
Advisory Support:
Provided continuous consulting services throughout the development lifecycle, from early-stage modeling to investor presentations.
Key Results
Validated Process
Performance
Atmospheric leaching showed promising recovery rates with reduced energy intensity compared to HPAL.
Improved
Sustainability Metrics
LCA revealed lower greenhouse gas emissions and water consumption due to closed-loop design and energy-efficient operations.
Economic
Competitiveness
TEA demonstrated the potential for reduced capital and operating expenditures versus HPAL, supporting a compelling investment case.
Patent
Readiness
Technical data packages supported intellectual property development and strengthened the client’s competitive position.
Business Impact
Our work enabled the client to:
- Advance an environmentally and economically attractive alternative to HPAL for nickel and cobalt extraction and advancement of sustainability in the metallurgical industry.
- Reduce development risk through robust process modeling and scenario-based evaluation.
- Build a strong foundation for pilot-scale testing, stakeholder and investor engagement, and eventual commercialization.
This case study highlights our ability to integrate technical, economic, and environmental assessments to accelerate the development of next-generation metallurgical technologies.
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