Abstract:
Nickel resources, as crucial strategic metallic minerals in China, have a significant impact on national economic security, defense capabilities, and resource sustainability. China has the largest demand for nickel in the world, yet its domestic resources are limited, accounting for only 4% of the global total. Approximately 90% of these resources are difficult to mine copper–nickel sulfide ores, while the remaining 10% are low–grade laterite nickel ores, resulting in a high reliance on imports. Regionally, China's nickel resources are mainly distributed in the northwest, southwest, and northeast regions, which account for 76.80%, 12.10%, and 4.90% of the national reserves, respectively. Nickel ore occurs primarily as copper–nickel sulfide ore and laterite nickel ore. The mineral composition of copper–nickel sulfide ores in China is relatively similar, with the main minerals including nickel pyrite, millerite, pentlandite, niccolite, nickel–bearing magnetite, magnetite, and chalcopyrite. Vein minerals mainly consist of serpentine, chlorite, and talc. Nickel generally coexists with copper and cobalt in sulfide form, and froth flotation is the primary beneficiation method. This article introduces five flotation methods: bulk flotation, selective flotation, gangue pre-rejection followed by flotation, stage grinding—floating, and flotation—gravity technology. These methods are applied to sulfide copper–nickel ores with different elemental compositions and mineral embedding characteristics. Bulk flotation is highly adaptable to various ores, while selective flotation is better suited for ores where copper grades exceed nickel grades. The gangue pre-rejection—flotation process is suitable for ores with high vein mineral content, whereas stage grinding—flotation is used for ores with complex mineral associations. Laterite nickel ores are divided into three layers: limonite, transition, and saprolite zones. Due to differences in mineral composition and content across these layers, distinct processing methods are required. The limonite layer had higher iron and cobalt contents but lower silicon, magnesium, and nickel levels, with a relatively uniform mineral composition. Iron occurs mainly as goethite and hematite, while nickel is mostly found in silicon and magnesium-bearing minerals, necessitating wet metallurgical processes. The transition layer exhibits intermediate elemental composition, with nickel mainly present in silicate minerals and partially in iron-bearing species. Effective recovery of valuable elements such as nickel minerals requires enhanced conditions—such as increased acidity, high temperature, and reduction to ensure full exposure of valuable elements, making combined wet-pyrometallurgical processes suitable. The saprolite zone is characterized by high silicon, magnesium, and nickel contents, low iron and cobalt levels, and highly variable mineral composition. Silicate minerals dominate, followed by iron oxides. Wet processing often results in excessive reagent consumption and complications due to the lower melting point of nickel compared to iron oxides. Therefore, pyrometallurgical processes are generally preferred. This provides a systematic overview of nickel mineral processing methods, analyzes their advantages and disadvantages, and proposes prospects for improving resource utilization, offering a reference for the treatment of various nickel ores.