Breakthrough in nickel Extraction Promises Greener Electrification
As the world transitions from fossil fuels to electricity to combat climate change, the demand for nickel, a crucial component in batteries, magnets, and stainless steel, is set to double by 2040.Though, conventional nickel production methods release approximately 20 tons of carbon dioxide per ton of nickel, posing a meaningful environmental challenge. Now, scientists at the Düsseldorf Max Planck Institute for Sustainable Materials (MPI-Susmat) have announced a potential game-changer: a carbon dioxide-free, energy-efficient nickel extraction process that can utilize previously unusable, low-grade ores.
The findings were published in the journal *Nature*.
The Hydrogen Plasma Revolution
The new method employs hydrogen plasma to extract nickel from ores in a single step, eliminating the need for carbon. Ubaid Manzoor, a doctoral student at MPI-Susmat and the study’s frist author, explains the core problem with current methods:
If we continue to produce nickel conventionally and use it for electrification, we only shift the environmental pollution from the transport to the metallurgical sector.
Ubaid Manzoor, MPI-Susmat
The new process slashes carbon dioxide emissions by 84% by removing the ore reduction and transport stages. Moreover, it is indeed up to 18% more energy-efficient as it avoids the repeated heating and cooling cycles common in traditional methods.
Did you know? Nickel is a silvery-white metal with a slight golden tinge. It is hard, malleable, ductile, and a fair conductor of heat and electricity.
unlocking Inferior Ores
Historically, the industry has favored high-quality ores due to the complexities of extracting nickel from lower-grade sources, which often contain nickel in complex silicates or iron oxides. Traditional methods involve multiple energy-intensive steps: calcination, melting, reduction, and refining. The MPI-Susmat scientists’ innovation allows for the processing of these inferior ores, which constitute approximately 60% of global nickel deposits, in a single arc furnace, yielding a high-quality ferronickel product.
Professor Isnaldi Souza Filho, group leader at MPI-Susmat and corresponding author of the study, elaborated on the process:
With the help of hydrogen plasma and by checking the thermodynamics within the arc stove, we succeed in convicting the complex crystal structure of the minerals into simpler ion shapes—and even without catalysts.
Professor isnaldi Souza Filho, MPI-Susmat
Scaling Up for a Greener Future
The next phase involves scaling the process for industrial use. Manzoor notes a critical aspect for triumphant scaling:
The ore is reduced exclusively on the reaction surface—not in the entire melting pool. For an industrial scale, it is indeed thus crucial that the non-reduced melt continuously reaches the reaction surface.
Ubaid Manzoor, MPI-Susmat
He suggests that established industrial methods like light sheets with high currents, electromagnetic stirring systems, and gas impulses can achieve this, facilitating integration into existing production facilities.
Pro Tip: Companies looking to adopt sustainable practices can explore partnerships with research institutions like MPI-Susmat to implement and refine innovative extraction processes.
Beyond Nickel: Applications and Implications
The ferronickel produced can be directly used in stainless steel manufacturing or further processed for battery materials and high-performance magnets. Even the slag generated during the reduction process has potential applications in the construction industry, such as in cement or brick production. Furthermore, the process is adaptable to other metals like cobalt, which are also vital for electromobility and energy storage.
The research was supported by an ERC Advanced Grant from the European Research Council.
