A Nickel Sulphate Hexahydrate Refinery Study
Disclaimer: This project was completed as a McMaster University fifth-year capstone project in cooperation with Hatch’s Hydrometallurgy Team in Mississauga, Canada.
Project Overview
The global market for nickel sulphate hexahydrate (NSH), an important pre-cursor component needed to create cathodes used in lithium-ion batteries, is experiencing significant growth due to the increasing demand for electric vehicles. Traditional NSH production methods rely on resource-intensive processes that significantly impact the environment. This scoping study, a collaboration between McMaster University and Hatch, Ltd., proposes a novel, sustainable design for a 50,018 tonne/year battery-grade (>99% purity) NSH refinery based in Sudbury, Ontario. The design prioritizes minimizing environmental impact while maintaining economic viability.
Utilizing Mixed Hydroxide Precipitate (MHP) feedstock, the proposed refinery employs acid leaching, solid-liquid separation, neutralization, solvent extraction, and crystallization to achieve >99.4% NSH purity, along with over 4,000 tonnes/year of 99.9% pure cobalt sulphate hexahydrate. A comprehensive Excel-based process simulation, including mass and energy balances, supports the design. Deliverables also include a Mechanical Equipment List, Process Design Criteria, and a Process Flow Diagram. Detailed cost estimates and environmental/safety analyses inform the decision of whether a feasibility study is necessary. The key findings of the project include a projected capital cost in Canadian dollars of $837 MM, annual cost of refinement of $761 MM, and estimated earnings of $266 MM, resulting in a compelling 37% IRR over 40 years and a 3-year breakeven point.
This scoping study lays the groundwork for a more sustainable and economically viable NSH production process, positioning Canada as a key player in the rapidly expanding battery materials market. The next phase will focus on detailed design and risk mitigation strategies.
