The Western Australian Nickel Laterite Projects - What Have We Learned?

Presently about 60% of the world's nickel resources are tied up with lateritic ores while about 25% of the world's nickel is produced from sulphides. Based on this the industry has to focus on improving lateritic nickel economics in order to maintain the high use of the metal worldwide. In 1997 three junior mining companies in Australia organised finance against all odds and commenced development of three separate nickel and cobalt extraction plants treating lateritic nickel ores. All three projects utilise similar pressure acid leaching (PAL) technologies while each has unique metal recovery technologies All projects have experienced numerous processing and maintenance related difficulties such that full ore throughput has been reached by only one operation after five years. This shortfall in performance has caused the owners considerable angst and financial pain. In 2000 Cawse went into receivership and was purchased by an international corporation. Recently, Bulong also went into receivership and has undergone an orderly shutdown, awaiting sale to a new buyer. Murrin Murrin has settled with its financiers and is in a position to operate as planned for many years forward. This paper will discuss a number of the technical difficulties that affect the ore preparation, PAL and solution treatment circuits of these plants. The objective is to identify the cause of some of the difficulties and propose possible solutions so that the next generation of lateritic operations can emerge as technically and, more importantly, economic successes. A number of these process improvements have been identified by the existing operators and in many instances have been or are being implemented into the existing operations.