Professional Documents
Culture Documents
INCO
NICKEL LATERITES
Formation & Mineralogy,
Exploration, Mining, and
Processing Method
March 2006
P.T. INCO
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accumulation of soil
Appropriate
rock type
Appropriate
weathering conditions
Appropriate
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Red Laterite
Limonite
zone
Saprolite
zone
Bedrock pinnacle
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MINERALOGY
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Spinels
Primary
igneous
minerals
Olivine
Pyroxene
Magnetite
Chromite
Hydrothermal
minerals
Serpentine
Talc
Chlorite
Laterite
weathering
minerals
Secondary:
Serpentine
Talc
Chlorite
Oxides &
Hydroxides
Nickel
Silicates
Hematite
Goethite
Limonite
Bauxite
Gibbsite
Garnierites:
Nepouite
Willemsite
Pimellite
Nimite
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H2O
Talc
En
Serp.
Chlor.
Brucite
PYX
Fs
Fo
OLIV
Fa
FeO
MgO
Magnetite
Magnesioferrite
Hematite
Fe2O3
Goethite
Limonite
Xanthosiderite
Esmeraldaite
H2O
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OLIVINES Formation
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OLIVINES Formation
Forsterite forms first
High melting temp.
Crystals
settle on
the bottom
of magma
chamber.
Original
Forsterite
composition
preserved
Crystals
allowed to
react with
magma
MAGMA
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ALTERATION OF OLIVINE
Alteration of Forsterite
+800C:
Fo to En
625-800C:
Fo to En to Talc
500-625C:
Fo to Talc
200-500C:
Fo to Serpentine
Magmatic
Hydro
thermal
H2 O
Serpentine
Talc
MgO
Fo
En
SiO2
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GARNIERITE GROUP
SiO2
Mg3Si4O10(OH)2.nH2O
Kerolite - Talc
Serpentine
Mg3Si2O5(OH)4
10A basal
spacing
GARNIERITES
Ni3Si4O10(OH)2.H2O
Pimelite
7A basal
spacing
MgO
Nepouite
Ni3Si2O5(OH)4
NiO
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Layer
Metamorphic
Grade
Thickness
Sea Level
2.0 km/sec
5.1 km/sec
Marine Sediments
Zeolite
Ocean basalts
0 4 km
1 2.5 km
Greenschist
3
Gabbros
6.7 km/sec
5 km
Amphibolite
4
8.1 km/sec
8.1 km/sec
Layered Peridotite
Mantle Peridotites
Oceanic Crust
5 8 km
0.5 km
Mohorovicic
Discontinuity
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Ni IN ULTRAMAFIC ROCKS
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WEATHERING
Types of weathering:
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CHEMICAL WEATHERING
1. Hydrolysis
Oxygen, carbon dioxide, ground water, dissolved acids attack the
minerals in the rock
2. Oxidation
Elements released by chemical weathering are oxidised
3. Hydration
Reaction with water adds the hydroxyl ion to newly formed minerals
4. Solution
The more soluble products of weathering are dissolved and removed
And the cycle continues .....
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Acidic
Rain
Acidic
Rain
ZONE OF OXIDATION
WATER TABLE
(Reducing conditions)
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Elemental Mobilities
Relative
Mobilities
(decreasing
Order)
Ca++
= 3.0
Na+
= 2.4
Mg++
= 1.3
K+
= 1.25
SiO2
= 0.20
Fe2O3 = 0.04
Al2O3 = 0.02
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1.
2.
3.
4.
5.
6.
Topography
7.
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Steep Hill
Gentle Hill
Depression / basin
Plateau
River Terrace
Dissected Plateau
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of rainfall
Ground porosity/permeability
Topographic characteristics
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WEATHERING OF
ULTRAMAFIC ROCKS
AND LATERITES
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WEATHERING OF OLIVINE
Sorowako Olivine:
FeO =
9.0%
Al2O3 =
0.4%
NiO =
0.37%
MnO =
0.12%
Cr2O3 =
0.02%
TiO2 =
0.02%
Replacements
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WEATHERING OF PYROXENE
Sorowako Pyroxene:
Opx
Replacements
Cpx
FeO = 6.0
2.5
Al2O3 = 3.2
3.5
CaO = 1.9
21.7
NiO = 0.08
0.05
MnO = 0.13
0.08
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Weathering of Serpentine
Serpentine: 3MgO.2SiO2.2H2O
Iron
containing serpentine
Nickeliferous
serpentine
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Ferric
Fe++
In olivine (MgO.FeO.SiO2) :
In chromite (FeO.Cr2O3) :
In ilmenite (FeO.TiO2) :
In magnetite (FeO.Fe2O3) :
Fe++
Fe++
Fe++
Ferrous
Fe+++
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Behaviour of Alumina
Spinel (MgO.Al2O3)
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Behaviour of Mn and Co
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Behaviour of Ni
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LATERITES
The term Laterite is derived from the Latin word later which
means brick
Currently, the term Laterite is used for soils that are rich in
sesquioxides of iron and aluminium, formed under the influence of
chemical weathering with special ground water conditions
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LATERITE PROFILE
Laterite Zones
Red Hematite
Yellow Limonite
Processes at work
Acidic environment
Collapsed profile
Soluble ions leached (Ca, Mg, Si, Na, K)
Insoluble ions concentrated (Cr, Al, Fe)
Mn, Co show supergene enrichment
Saprolite zone
Alkaline environment
Un-collapsed profile
Leaching / residual concentration in progress
Boulder formation
Ni shows supergene enrichment
Bedrock zone
Alkaline environment
Joints / fractures exposed to U/G water
Chemical attack is just beginning
Channelways provide removal of dissolveds
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EAST BLOCK
SERPENTINISED
DEPTH (m)
10
15
20
Iron cap
Limonite
Overburden
Limonite ore
Saprolite Ore
Bedrock
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SILICATE
(eg New Caledonia)
DEPTH (m)
0
Iron cap
Colluvium
Red
limonite
Ferruginous
zone
Rocky
ore
Bedrock
Limonite
overburden
Limonite
Smectite
zone
Saprolite
Earthy
ore
Ore with
boulders
40
OXIDE
(eg Moa Bay)
Cuirasse
Yellow
limonite
20
CLAY
(eg Murrin Murrin)
Saprolite
(Serpentine,
chlorite,
smectite)
Bedrock
Bedrock
Fe
SiO2
SAPROLITE
LIMONITE
Transition zone
PERCENTAGES
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MgO
AlO2O3
-6
-4
-2
DEPTH IN METRES
10
12
14
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SAPROLITE
2.5
Supergene Ni
enrichment
2.0
MnO
1.5
Ni
Transition zone
PERCENTAGES
3.0
1.0
0.5
Co
0.0
-6
-4
-2
DEPTH IN METRES
10
12
14
P.T. INCO
RATES OF LATERISATION
m m o f L a te rite
100,000
100 metres
10,000
10 metres
1,000
1 metre
Based on water
compositions of
well-drained
Ultramafics
100
Based on mineral
solubilities in the
Laboratory
10
1
10
1,
10
,0
,0
00
00
00
0,
00
00
00
0,
,0
00
10
1,
10
10
TIME IN YEARS
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Sorowako
WB
EB
Sorowako Plant
Petea Area
Mahalona
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The best method: test pit or large diameter (20 cm) core drilling.
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FIGURE - 1
Revised: May 6, 2001
MINING ASPECTS
(Mineability,
Dilution)
PROBABLE
MINERAL
RESERVE
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PROVEN
MINERAL
RESERVE
MINING ASPECTS
(Mineability,
Dilution)
INFERRED
MINERAL
RESOURCE
Low
INDICATED
MINERAL
RESOURCE
Medium
MEASURED
MINERAL
RESOURCE
High
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To obtain:
Detailed
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Albania
Greece
India Burma
Cuba Dominican
Philippines
Republic Ivory Coast
Guatemala
Indonesia
Columbia VenezuelaBurundi Ethiopia
Zimbabwe
PNG
Brazil
New
Madagascar
Caledonia
Australia
Producing Countries
Non Producing Countries
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CUBA
PHILIPPINES
INDONESIA
NEW CALEDONIA
AUSTRALIA
LATERITES
SULPHIDES
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Mt Resource
% Ni
Mt Ni
Caribbean
2785
1.26
35.0
25
New Caledonia
1890
1.52
28.7
20
Indonesia
1401
1.63
22.8
16
Philippines
1162
1.30
15.1
11
Australia
1144
0.95
10.9
Africa
800
1.33
10.7
C. & S. America
Other
661
539
1.60
1.08
10.6
5.8
8
4
10382
1.34
140
100
Total
P.T. INCO
C. & S.
America
8%
Africa
Other
4%
Caribbean
25%
8%
Australia
8%
Philippines
11%
Indonesia
16%
New
Caledonia
20%
P.T. INCO
Mt
Ore
%
Ni
Contained
Nickel
Relative
%
SULPHIDES
10,594
0.58
62
31%
LATERITES
10,382
1.32
140
69%
TOTAL
20,976
0.96
202
100%
P.T. INCO
LIM Non-producing
SAP Non-producing
2.8
SLN Hi grade
2.6
Taganito
2.4
2.2
% Ni Grade
Koniambo
Hinatuan
Rio Tuba
Puma
Onca
2.0
Funguesso
C.Matoso
R 1-5
C 1-5
1.8
Soroako
1.6
Tocantins
Loma
B 1-5
1.4
Codemin
1.2
M 1-5
Moa
Inco Pomalaa
Bahodopi
Exmibal
Falcondo
Inv.
Cupey
SOA
Gag
Ramu R.
1 B lb Ni
0.6
0
50
Raventhorpe
6-20
100
N.Cal.
Indep.
Mindanao
Ambatovy
Murrin M. 6-20
2 B lb Ni
Bulong
6-20
Goro Ni
Palawan
Apo
Nicaro
0.8
10 B lb Ni
Sipilou
Soroako
Prony
Inco Pomalaa
P.Gorda
1.0
15 B lb Ni
PTAT
Larco
Marlboro
Pinares
des Mayari
5 B lb Ni
Mt.Marg.
Cawse 6-20
150
200
250
300
350
400
450
P.T. INCO
PRIMARY Ni PRODUCTION
WORLD Ni RESOURCES
60%
70%
LATERITE
SULPHIDE
LATERITE
40%
SULPHIDE
30%
P.T. INCO
Country
Producers
Mt Ni
% of
world
Indonesia
PT Inco; ANTAM
79,100
16.9
Cuba
Cuba Nickel
75,000
16.0
Australia
67,383
14.4
Japan
63,000
13.5
New Caledonia
Eramet/SLN
61,500
13.2
Columbia
46,900
10.0
Brazil
Anglo; others
30,000
6.4
27,227
5.8
Venezuela
17,200
3.7
467,310
100%
TOTAL
INDONESIA
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SERAWAK
HALMAHERA
SULAWESI
WEDA BAY
SOROAKO
KALIMANTAN
SUMATRA
GEBE
WAIGEO IRIAN JAYA
OBI GAG
BAHODOPI
POMALAA
JAVA
TIMOR
500km
PNG
SENTANI
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PTI Concession
Malili
Original Concession
6,600,000 Ha
Current Concession
218,529 Ha
(3.3%)
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Matano
Matano Lake
Petea
Lampesue N&S
WB EB
Processing Plant
Lingkona
Mahalona
Malili
Towuti Lake
Tanamalia
Lasubonti
Lingke
Lengkobale
P.T. INCO
Equipment
BACKHOE
FRONT SHOVEL
TRUCK
DOZER
LOADER
Type
Total Unit
11 m3 bucket
4 m3 bucket
11
11 m3 bucket
50 tons payload
85 tons payload
51
350 HP
34
550 HP
200 HP
11 m3 bucket
6.5 m3 bucket
3.5 m3 bucket
P.T. INCO
EXPLORATION
DRILLING
Ore Body
modeling
&
Mine Planning
MINING
(ORE DIGGING)
SAPROLITE
Land
CLEARING
STRIPPING
of
Overburden
capping
OVERBURDEN
DISPOSAL/
DUMPS
FINAL MINE
PRODUCT
to
WET ORE
STOCKPILES
Capacity : 1million
tons
SCREENING
(ORE
UPGRADING)
(4 active
screening
plants)
Mine Revegetation
Mining Process
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GEOLOGIST
Exploration (Mapping, Drilling,
Logging, Geological Evaluation,
Geophysics)
MINE ENGINEER
Mine Planning (Life of Mine,
LTP/STP, Equipment Calculation,
Design of mine pit, roads, dumps,
drainage, quarry, etc)
Blasting
Mine Dispatch System (Modular
Mining System).
Geologist)
Ore Blending
Mining Operation
Production Statistic and Cost
Control
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Rehabilitation work
at disposal area
Before rehabilitation
Land preparation
Vegetation development
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PROCESSING OF Ni LATERITES
Pyrometallurgical processing
(Ore is melted)
Production
of Ferro-nickel
Production
of Ni-S matte
Hydrometallurgical processing
(Ore is leached with acid solutions)
P.T. INCO
Nickel Laterite
Mining
Deposit
uniformity
Upgrading
Ore/Con
shipping
Processing cost
Ni recovery
Capital cost
Modest per lb of Ni
High per lb of Ni
Project size/life
P.T. INCO
Processing
Drying
To reduce moisture content to +/- 20%.
To reject high olivine/low Nickel rocks
To blend the ore
Reduction
To further reduce moisture content to ~0%.
To remove water crystal (LOI/Loss on Ignition)
To further blend the ore
Convert/reduce oxides to metallic form
Finalize blending recipe for smelter feed (addition of Carbon/coal and
Sulfur)
Smelting
To remove remaining LOI
To complete reduction process
To melt sulfide and metallic phases to form a single liquid matte phase.
To melt the remaining oxide phases to form a single liquid slag phase.
To separate the matte and slag phase based on density differences.
To discard the slag containing only small amount of nickel.
To tap matte containing most of nickel for further processing in the
converters.
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MELTING PROCESS
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Thank You