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Unlocking the Nickel Value of Ultramafic Resources Through Innovative Thermal Treatment Process
Wei Lv1, Fanmao Wang2,3, Brian Makuza1
1Department of Materials Science & Engineering, University of Toronto, Toronto, ON, Canada.
Communications Engineering
|June 15, 2026
Summary
A new solid-state process efficiently extracts nickel from low-grade ores using iron. This sustainable method offers rapid processing and low temperatures, crucial for battery production and a stable nickel supply chain.
Area of Science:
- Metallurgical Engineering
- Sustainable Materials Science
- Green Chemistry
Background:
- Nickel is vital for stainless steel, alloys, and increasingly for secondary batteries powering clean energy technologies.
- Declining high-grade nickel resources and rising demand necessitate sustainable extraction methods for low-grade ores.
- Existing methods face challenges with environmental impact and resource availability, highlighting the need for innovation.
Purpose of the Study:
- To develop an environmentally benign, low-temperature process for nickel extraction from low-grade ultramafic ores.
- To utilize metallic iron as a cost-effective and sustainable nickel getter for high-value nickel recovery.
- To contribute to a decarbonized metal production pathway and enhance the global nickel supply chain resilience.
Main Methods:
- A predominantly solid-state process operating at low temperatures (<950°C) was employed.
- Metallic iron was used as a nickel getter to selectively partition nickel into ferronickel alloys.
- Process parameters (temperature, atmosphere, iron addition) were optimized for selective nickel partitioning and sulfur sequestration.
Main Results:
- The process successfully extracted nickel from low-grade ultramafic ores, producing ferronickel alloys with 16-24% nickel content.
- Key advantages include rapid processing time (~3 hours), low operational temperatures, and elimination of sulfur dioxide (SO2) emissions.
- The recovered ferronickel is suitable for conversion to battery-grade nickel via conventional refining techniques.
Conclusions:
- The developed low-temperature solid-state process offers a sustainable and efficient route for nickel extraction from unconventional resources.
- This method supports decarbonized metal production and strengthens the global nickel supply chain for clean energy applications.
- The technology, validated at a mini-plant scale, expands nickel extraction options and promotes resource circularity.
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