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US 2025/0109037 A1Published application
Processes and systems for producing a nickel sulfate product
AssigneeBASF SE
InventorsSabine Frischhut, Julia Hofinger, Ralf Boehling, Stefan Pichlmair
Life of this patent
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Abstract
The present disclosure is directed to methods and systems for reacting elemental nickel particles with sulfuric acid and hydrogen peroxide solutions to produce nickel sulfate products, for example, nickel sulfate products suitable for battery materials.
Claims15
A method for preparing a nickel sulfate product, the method comprising
- introducing nickel particles from a handling device (1, 20) into a vessel (2, 21) comprising a separation device (4, 23) therein, wherein the separation device (4, 23) controls the flow of the nickel particles through the vessel (2, 21), and the nickel particles form a fixed bed (3, 22) on the separation device (4, 23);
- introducing an inertization gas (8) into the vessel (2, 21) through one or more gas inlets;
- introducing a sulfuric acid solution (9, 28) into the vessel (2, 21) through one or more liquid inlets;
- introducing a hydrogen peroxide solution (10, 29) into the vessel (2, 21) through one or more liquid inlets;
- wherein the sulfuric acid solution (9, 28), the hydrogen peroxide solution (10, 29), and the nickel particles react to reduce the size of the nickel particles to form a nickel sulfate slurry, to dissolve the nickel particles to form a nickel sulfate solution, or any combination thereof (11, 24);
- wherein the nickel sulfate slurry, the nickel sulfate solution, or any combination thereof (11, 24) pass through the separation device (4, 23);
- and
- transferring the nickel sulfate slurry, the nickel sulfate solution, or any combination thereof (11, 24) out of the vessel (2, 21) at one end into an external circulation loop (6, 25) and back into the vessel (2, 21) at an opposite end through the external circulation loop (6, 25) continuously until the nickel sulfate product is ready for collection.
5 more elements
A system for preparing a nickel sulfate product, the system comprising:
- a first reaction vessel (21) with a separation device (23) therein for controlling the flow of nickel particles therethrough;
- wherein the first reaction vessel (21) is configured to form a fixed bed (22) of the nickel particles on the separation device (23);
- a first handling device (20) for introducing the nickel particles into the first reaction vessel (21);
- a first external loop (25);
- liquid inlets positioned at the upper part of the first external loop (25) for introducing a sulfuric acid solution (28), a hydrogen peroxide solution (29), and water (30), respectively, into the first reaction vessel (21);
- wherein the separation device (23) is configured to let nickel sulfate slurry and/or nickel sulfate solution containing fines (24) pass through and exit the vessel (21) at the bottom and enter the first external loop (25);
- wherein the first external loop (25) is configured to transfer the nickel sulfate slurry and/or the nickel sulfate solution containing fines (24) back into the first reaction vessel (21) at the top of the first reaction vessel (21);
- wherein the system further comprises one or more pumps (26) for pumping the nickel sulfate slurry and/or the nickel sulfate solution containing fines (24) through the first external circulation loop (25), and wherein the pumps (26) are external to the first reaction vessel (21);
- wherein the system further comprises one or more heat exchange devices (27) for adjusting the temperature of the nickel sulfate slurry and/or the nickel sulfate solution containing fines (24), and wherein the heat exchange devices (27) are external to the first reaction vessel (21);
- and
- wherein the system further comprises a second reaction vessel (31), a second handling device (20) for charging the second reaction vessel (31) with additional nickel powder, liquid inlets for dosing sulfuric acid (28) and hydrogen peroxide (29) into the second reaction vessel (31), and a second external loop (35);
- wherein the first external loop (25) is configured to discharge part of the nickel sulfate slurry and/or the nickel sulfate solution containing fines (24) from the first reaction vessel (21) into the second reaction vessel (31);
- wherein the second external loop (35) is configured to recycle nickel sulfate solution from one end of the second reaction vessel (31) to the other end of the second reaction vessel (31) via a pump through a separation device and a heat exchanger (33);
- and
- wherein the second external loop (35) comprises an outlet (34) for discharging nickel product solution from the second reaction vessel (31).
12 more elements
Dependencies are inferred from the claim text.