Geology, Technology and Economics –
Finding the Balance
Nickel Laterites in SE Asia
Presented by:
Mick Elias
Principal Consultant
CSA Global
BALI 2013
East Asia: Geology, Exploration Technologies and Mines
May 27, 2013
• What are nickel laterites and how do
they form?
• Range of deposit types
• Global distribution of lateritic nickel resources
• Exploration and resource delineation
• Processing options for nickel laterite ores
• Laterite processing – future trends
• What helps to create a successful nickel
laterite venture?
PRESENTATION OUTLINE
Chemical Weathering
General processes Effects in ultramafic rocks
1. Leaching of mobile constituents:
alkalis, alkaline earths
Breakdown of olivine, pyroxene, serpentine
and leaching of Mg, Ni, Mn, Co
2. Formation of stable secondary
minerals: Fe and Al oxides, clays
Goethite formation, smectite formation,
adsorption of Ni from solution
3. Partial leaching of less mobile
components: silica, alumina, Ti
Leaching of silica in humid climates in well-
drained locations
4. Mobilisation and partial
reprecipitation of redox-controlled
constituents: Fe, Mn
Precipitation of Mn oxides and adsorption of
Ni and Co from solution
5. Retention and residual concentration
of resistant minerals: zircon,
chromite, quartz
Residual chromite concentration
SCHEMATIC LATERITEPROFILE
SCHEMATIC LATERITEPROFILE COMMON
NAME
APPROXIMATE ANALYSIS
(%)
REDLIMONITE
Ni
<0.8
0.8to
1.5
1.5to4
25to 40
5to15
1.8to3
0.3 0.01 535to45
10to25
15to35
0.1to
0.2
40to50
0.5to 5
Co
<0.1
Fe
>50
MgO
<0.5
YELLOWLIMONITE
TRANSITION
SAPROLITE/GARNIERITE/SERPENTINE
FRESHROCK
0.02to
0.1
TROPICAL LATERITE PROFILE
MAIN NICKEL-BEARING MINERALS
Goethite (Fe,Al)O.OH.xH2O Up to 2.0% Ni, 0.2% Co
Mn oxides (Co,Ni)O.2MnO2.xH2O Up to 16% Ni, >4% Co
Nontronite Fe (Ca,Na,Mg,Al) clay Up to 4% Ni
Ni serpentine (Mg,Fe) hydrated silicate Up to 12% Ni
“Garnierite” Hydrated Mg silicate Up to 30% Ni
Chlorite (Mg,Fe,Al) hydrated silicate Up to 15% Ni
• What are nickel laterites and how do
they form?
• Range of deposit types
• Global distribution of lateritic nickel resources
• Exploration and resource delineation
• Processing options for nickel laterite ores
• Laterite processing – future trends
• What helps to create a successful nickel
laterite venture?
PRESENTATION OUTLINE
CLASSIFICATION OF NICKEL LATERITES
Ore mineralogy Fe Silica Magnesia
Global
mean Ni
grade
OXIDE
(“LIMONITE”)
Fe hydroxides
(goethite)
High Low Low 1.06%
CLAY Nontronite,
smectite
Low High Moderate 1.21%
SILICATE
(“SAPROLITE”)
Hydrated Mg-Ni
silicates (incl.
garnierite)
Low High High 1.79%
Oxide – Ambatovy, Madagascar
Clay – Bulong, Australia
Silicate laterite – New Caledonia
Garnierite veins, New Caledonia
0
20
40
DEPTH (m)
SILICATE
(eg New Caledonia)CLAY
(eg Bulong)OXIDE
(eg Ambatovy)
Cuirasse
Red
limonite
Yellow
limonite
Earthy
ore
Ore with
boulders
Rocky
ore
BedrockBedrock
Saprolite
(Serpentine,
chlorite,
smectite)
Smectite
zone
Ferruginous
zone
Colluvium
Bedrock
Saprolite
Limonite
Limonite
overburden
Iron cap
Nickel Laterite Profiles
• What are nickel laterites and how do
they form?
• Range of deposit types
• Global distribution of lateritic nickel resources
• Exploration and resource delineation
• Processing options for nickel laterite ores
• Laterite processing – future trends
• What helps to create a successful nickel
laterite venture?
PRESENTATION OUTLINE
GLOBAL NICKEL RESOURCES
CUBA
INDONESIA
AUSTRALIA
LATERITES SULPHIDES
NEW CALEDONIA
PHILIPPINES 22°N
22°S
Sulphides
30%
Laterites
70%
GLOBAL NICKEL RESOURCES(Contained Nickel)
Silicate
30%
Limonite
70%
Total 160 Mt Ni
2700 Mt
1.79% Ni
48 Mt Ni
9600 Mt
1.17% Ni
112 Mt Ni
GLOBAL LATERITE RESOURCES(Contained Nickel)
Africa
Americas
Balkans
Other
Brazil
Cuba
Australia
New Caledonia
Indonesia
Philippines
silicate
limonite
LATERITE RESOURCES BY REGION(Contained Nickel)
2.49%
1.38%
1.88%
1.36%
1.40%
1.19%
ETOILE DU NORDKAALA
KONIAMBO
NEW CALEDONIA
NICKEL LATERITE LOCATIONS
ILE ART
POUM
TIEBAGHI
TAOMOUAZANGOUOUATILOU
TCHINGOU
PLAINE DES GAIACS
BOULINDAME MAOYA
LE CAP
PORO
BOURAIL
NINGUA
MT DO
OUENGHI
THIO MISSION
N'GOYE
PORT BOUQUET
OUINNE
BAIE N'GOPLAINE DES LACS
MT DORE/PLUM
SLN DONIAMBO SMELTER
GORO
HARICOT NORD
PORT BOISE
PRONY
MONEOKOPETO
CAP BOCAGE
Ophiolites - Ni Laterite potential
Operating Mines
Not in Production or closed
KOUAOUA
BOAKAINEPOYA
0 50 100
kilometres
BOGOTA / CANALA
NAKETYTHIO PLATEAU
TONTOUTA
NOUMEA
N
0 5 0 0 1 0 0 0 k m
S C A L E
OPHIOLITES
JAVA
TIMOR
SULAWESI
KALIMANTAN
OBI
HALMAHERA
WAIGEO
IRIAN JAYA
CYCLOOPSGAG
DISTRIBUTION OF OPHIOLITES IN INDONESIA
N
0 2 0 0 4 0 0 km
S C A L E
OPHIOLITE BELTS
LUZON
Manila
MINDOROSAMAR
PALAWANNEGROS
MINDANAO
KALIMANTAN
NONOC
OPHIOLITE BELTS OF THE PHILIPPINES
• What are nickel laterites and how do
they form?
• Range of deposit types
• Global distribution of lateritic nickel resources
• Exploration and resource delineation
• Processing options for nickel laterite ores
• Laterite processing – future trends
• What helps to create a successful nickel
laterite venture?
PRESENTATION OUTLINE
AUGER, TEST PITTING
DIAMOND DRILLING
SAMPLING CORE
ORE DELINEATION
• What are nickel laterites and how do
they form?
• Range of deposit types
• Global distribution of lateritic nickel resources
• Exploration and resource delineation
• Processing options for nickel laterite ores
• Laterite processing – future trends
• What helps to create a successful nickel
laterite venture?
PRESENTATION OUTLINE
TROPICAL LATERITE PROFILE
LATERITE PROCESSING OPTIONS
Ferronickel smelting
Matte smelting Pyrometallurgical processes
Blast/electric furnace (NPI)
Caron process
High pressure acid leach
AMAX process Hydrometallurgical processes
Atmospheric leach
Heap leach
Sorowako smelter, Indonesia
Murrin Murrin HPAL Plant
FeNi dominates as a finished product
Ni output as % of total laterite
Ferronickel smelting (incl NPI) 60
Matte smelting 14
Ammonia leaching 14
Acid leaching 12
2008 Figures
CSA, CRU Analysis
World Nickel Production by Ore Type
30.0%
32.0%
34.0%
36.0%
38.0%
40.0%
42.0%
44.0%
46.0%
48.0%
50.0%
0
100
200
300
400
500
600
700
800
900
1990 1995 2000 2005 2009
% L
ate
riti
cN
i
ton
nes N
i ('
000)
Sulphide
Laterite
% Laterite
Data: CSA and CRU Analysis
ACID LEACHING• Acid consumption
• High metal recoveries
• By-product cobalt
• Tailings disposal
• Effluent treatment
• Technology/cost risk?
• Ore composition
(Mg, Al)
CARON PROCESS• Energy (dry and roast)
• Capital cost of front end
• Poor cobalt recoveries
• Mechanical and process
reliability due to high
temperatures and
complexity
• Ore composition (Si, Ni)
SMELTING• Energy (dry and smelt)
• Simple, robust process
• FeNi suited to S/S
production
• No by-product credits
• Ore composition (Mg, Si)
• High Ni grades (upgrading
possible)
Nickel Laterites Processing Issues
CAPITAL AND OPERATING COSTS
Capex
US$/annual lbOpex
FeNi 30 – 40 Moderate
Ni pig iron (BF) 10 – 15? High
HPAL 30 – 40 Moderate
Existing Operations
• China (> 20 producers?)
• PT Indoferro (Cilegon) – 6000 tpa Ni
Commentary
• Chinese pig iron Ni production has increased from 30kt Ni in 2006
to an estimated 260kt in 2011
• Low-quality product, but electric furnaces capable of higher
quality product
• High cash costs ~ US$8 to 13/lb Ni
• Swing producer and potentially caps price spikes
Nickel Pig Iron
NPI PRODUCTION COSTS
Data: CRU Analysis
CHINESE NICKEL PIG IRON FILLS THE GAPS
(metric tonnes)
CHINESE NICKEL ORE IMPORTS
Source - INSG
(ktpa Ni contained)
MAJOR CHINESE NPI PRODUCERS
Source - Antaike, company reports, Hatch
188
(ktpa nickel contained)
PLANNED NPI PROJECTS IN CHINA
Source - Antaike, company reports, Hatch
620
2011 NICKEL MINE PRODUCTION
CountryNickel in ore mined
(‘000t)
Indonesia 294
Russian Federation 270
Philippines 245
Canada 223
Australia 201
New Caledonia 128
Brazil 102
Total World Mine production 1896
• What are nickel laterites and how do
they form?
• Range of deposit types
• Global distribution of lateritic nickel resources
• Exploration and resource delineation
• Processing options for nickel laterite ores
• Laterite processing – future trends
• What helps to create a successful nickel
laterite venture?
PRESENTATION OUTLINE
Technology Trends
Smelting (FeNi and matte)
• Well proven low risk technology
• Strong energy dependence
HPAL
• Proven but high risk technology
• High capital exposure
Ni pig iron
• Well proven low risk technology
• Low cap costs but high op costs
• Production will be Ni price
dependent
• Environmental concerns (trend
towards EF)
• Trend to higher quality product
reduces unit cost
Technology Trends
Atmospheric Leach
• Acid – key capital and operating
cost driver
• Capital and operating costs – lower
than HPAL
Heap Leach
• Ore type critical for heap
permeability
• Similar cost drivers
Emerging technologies
• Direct Nickel
• Direct reduction nickel (DRN)
• What are nickel laterites and how do
they form?
• Range of deposit types
• Global distribution of lateritic nickel resources
• Exploration and resource delineation
• Processing options for nickel laterite ores
• Laterite processing – future trends
• What helps to create a successful nickel
laterite venture?
PRESENTATION OUTLINE
Ingredients of a successful laterite project
Ore quality
• Grade
• Consistency
• Ore and overburden thickness
• Mineralogy
• Deleterious elements
Project scale
• Resource size
Ingredients of a successful laterite project
Choice of project flowsheet
• Combination of geological,
mineralogical and mining factors
• Technical and engineering factors
Location and infrastructure
• Should address flowsheet
requirements
Environmental considerations
• processing, waste disposal and
closure issues
