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Sustainable nickel enabled by hydrogen-based reduction
U Manzoor1, L Mujica Roncery2, D Raabe1
1Max Planck Institute for Sustainable Materials, Düsseldorf, Germany.
Nature
|April 30, 2025
Summary
A new hydrogen-plasma method efficiently extracts nickel from laterites, significantly reducing carbon dioxide emissions and energy use. This sustainable process supports the growing demand for nickel in renewable energy technologies.
Area of Science:
- Metallurgical Engineering
- Sustainable Energy Materials
- Green Chemistry
Background:
- Nickel is essential for sustainable energy technologies, with demand projected to surpass 6 million tons annually by 2040.
- Current nickel production methods are carbon-intensive, emitting approximately 20 tons of CO2 per ton of nickel.
- Extracting nickel from low-grade laterite ores presents significant challenges for sustainable production.
Purpose of the Study:
- To develop a novel, sustainable method for extracting nickel from laterite ores.
- To reduce the environmental impact of nickel production, specifically CO2 emissions and energy consumption.
- To streamline the nickel extraction process by integrating multiple metallurgical steps.
Main Methods:
- A fossil-free hydrogen-plasma-based reduction technique was employed for nickel extraction.
- Calcination, smelting, reduction, and refining were combined into a single-step metallurgical process within one furnace.
- Thermodynamic control of the furnace atmosphere was utilized for selective nickel reduction.
Main Results:
- High-grade ferronickel alloys were produced with fast reduction kinetics.
- The process yielded alloys with minimal impurities (<0.04% silicon, ~0.01% phosphorus, <0.09% calcium), eliminating the need for further refining.
- The method demonstrated potential for up to 18% greater energy efficiency and an 84% reduction in direct CO2 emissions compared to conventional practices.
Conclusions:
- The hydrogen-plasma reduction method offers a sustainable pathway for nickel extraction from laterites.
- This innovative approach addresses the environmental concerns associated with nickel production, balancing its critical role in sustainable energy.
- The integrated, single-step process significantly improves efficiency and drastically cuts carbon emissions, paving the way for greener nickel supply chains.
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