Do you remember the frustration of opening an exciting gift only to read the words, ‘batteries not included’? What usually followed was a desperate search through drawers and cupboards – and if none were found, the remote control or another household item would be sacrificed to power a few hours’ entertainment.
Battery research and development has revolutionized energy storage in the last decade. Today, batteries hold more energy and charge far more efficiently than ever before, taking them from the realm of toys and CD players to fueling electric cars and large trucks. Of course, this is a great thing for the planet, as electric mobility drastically cuts carbon dioxide (CO2) emissions! But all these batteries need to be manufactured – and that requires a lot of metal.
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Nickel’s evolving future
One of the base metals that make up a battery is nickel, also used in large quantities for steelmaking. In 2021, battery production accounted for 5% of global nickel production, but this percentage is expected to treble by 2025 to reach 15%. However, there’s a catch. Deposits of high-grade ore are becoming less common, and are unlikely to be able to keep up with rising demand in future. Producers are increasingly forced to rely on nickel laterite ores, which include a lot of other elements such as iron and cobalt and relatively small proportions of nickel. There are vast quantities of these laterite ores, but their low nickel content makes them trickier and more resource-intensive to process.
When ores contain less nickel, efficiency becomes extremely important. The efficiency of the
mining process is defined by the ore’s mineralogical composition – and of course, no producer wants to mistakenly discard ores as waste, so it’s vital to characterize them accurately. The answer? An effective analytical strategy.
Building your analytical strategy
While it is possible to start small with better analysis – and improving one aspect at a time is very effective – the best strategy will always be holistic. By thinking in terms of overall processes, it’s possible to maximize efficiency and reduce waste through a system of on-line instruments that enable real-time process control, and laboratory instruments where necessary to provide more in-depth data.
Working with nickel laterites means that mineralogy is key, making X-ray diffraction (XRD) analysis an ideal solution. XRD is a fast, powerful technique, and modern instruments deliver reliable mineralogical composition data in minutes. This makes it perfect for process control as well as research. It’s also possible to run multiple evaluation methods at the same time, which is very practical in a busy industrial environment.
XRD also pairs well with other analytical methods, such as X-ray fluorescence (XRF) for determining elemental composition, or pulsed fast and thermal neutron activation (PFTNA) for controlling basicity (MgO/SiO2), ore grade (Fe/Ni ratio), and moisture levels in real time. When installed at each appropriate stage as part of a holistic analytical strategy, XRD – and the other techniques mentioned – can transform an inefficient process or entire plant. The results are reduced energy use, less waste, higher and more consistent quality, and an overall lower carbon footprint.
The table below illustrates the value delivered by mineralogical monitoring using XRD (König, 2021). It’s clear that there is value in applying this versatile analytical tool to many different phases of metal production, especially in nickel laterite mining.
Opportunities and challenges
One of the most dynamic areas of change in modern industry is the automation of processes, and the next generation of industrial production defined by this automation has come to be known as ‘Industry 4.0’.
The significant increase in efficiency offered by automation and process control will play a large role in the mining industry's efforts to become more sustainable in the short- to mid-term. The ability to save energy, lower resource use, and waste, and (often) operate at consistently higher speed has great potential for lowering the overall carbon footprint of the industry, and also offers many benefits for individual producers thanks to reduced costs.
However, it can be difficult for decision-makers to act with confidence during this current stage of transition, and it’s important for producers to keep in mind the need to future-proof their strategy. Keeping up with technology provides a real market advantage, especially as an early adopter, but at a time when costs are already high, no-one wants to invest in systems that will quickly go out of date.
Expert advice for a future-proof strategy
The answer to this dilemma is twofold: firstly, expert advice is key. Secondly, investing in flexible solutions – with automation support built in – goes a long way toward mitigating risk. As experts in automated processes, we understand how to create holistic analytical systems that offer automation support, customized to our customers’ needs and applications.
Our experts are available to give advice and support long after an instrument is installed, and we offer guidance on which instruments are best suited for each application. From a single X-ray diffractometer to a fully automated laboratory, our solutions help our customers to drive efficiency and create value for the future.
To discover how better analysis could transform your mining operations, contact us today for expert advice.
It’s clear that there is value in applying this versatile analytical tool to many different phases of metal production, especially in nickel laterite mining.
