Patents Assigned to Vale Inco Limited
  • Patent number: 8557019
    Abstract: A method for producing metal oxide from a metal salt selected from nickel hydroxide, cobalt hydroxide, mixed nickel-cobalt hydroxide, nickel carbonate, cobalt carbonate or mixed nickel-cobalt carbonate includes providing a mixture of the metal salt, mixing the metal salt with a binder selected from an inorganic binder or an organic binder, forming the mixture into agglomerates, and calcining the agglomerates to produce metal oxide. Another method for making metallic nickel or cobalt includes providing the above metal salt, mixing the metal salt with the above binder to form a mixture, optionally adding water, forming the mixture into agglomerates, drying the agglomerates, adding an effective reducing amount of coke and/or coal and directly reducing the dried agglomerates with an effective amount of heat to produce metallic nickel and/or cobalt. Coke particles may be added to the mixture prior to agglomeration.
    Type: Grant
    Filed: April 15, 2009
    Date of Patent: October 15, 2013
    Assignee: Vale Inco Limited
    Inventors: Geoffrey Edwin Osborne, Ahmed Vahed, Samuel Walton Marcuson, Wanda Agnieszka Baczkowska, Emmanuel Nii Tackie
  • Patent number: 8147782
    Abstract: A process for producing a purified nickel hydroxide precipitate from a nickel-containing leach solution with impurities including one or more of the following: manganese, copper, zinc, iron and/or cobalt, so that the purified nickel hydroxide is suitable for pelletization with iron-containing ores and/or stainless steel production, includes treating the leach solution with a base to form a slurry of mixed hydroxide precipitate and low-nickel barren solution, thickening the slurry to form filter cake, washing the filter cake and contacting it with acid to dissolve nickel and other metals to produce a concentrated nickel-containing solution, subjecting the concentrated nickel-containing solution to solvent extraction with an organic acid extractant to remove metals other than nickel from the nickel-containing solution and form a solvent extraction raffinate of purified nickel solution and treating the solvent extraction raffinate with a base to precipitate the purified nickel hydroxide precipitate.
    Type: Grant
    Filed: September 23, 2008
    Date of Patent: April 3, 2012
    Assignee: Vale Inco Limited
    Inventors: Marc Murray Rishea, Indje Ognianov Mihaylov, Mohamed Buarzaiga, Flavia Dutra Mendes
  • Patent number: 8043585
    Abstract: A process for recovering metals such as Ni, Co, Mn, Cu, Zn, among others, through precipitation as sulphides, enabling recovery of magnesium in the form of hydroxide, carbonate and oxide and providing recovery of sulphate as gypsum and ammonium sulphate. Liquid phase, after full treatment, comprises recovered water with a quality proper for total reuse in industrial process. This process of liquid and solid effluent treatment is provided with flexibility to process several types of effluents presenting wide variations in their chemical composition.
    Type: Grant
    Filed: January 9, 2009
    Date of Patent: October 25, 2011
    Assignee: Vale Inco Limited
    Inventors: Salomao Solino Evelin, Roberto Mattioli Silva
  • Patent number: 7901484
    Abstract: A hydrometallurgical resin-in-leach (RIL) process for directly recovering nickel and/or cobalt. Simultaneous pulp leaching by adding an acid or base, dissolves the metals of interest with adsorption of the metals rendered soluble in on ionic exchange resin. Following elution of the changed resin, purification of nickel and cobalt present in the eluate can be recovered by conventional methods, such as precipitation, extraction by solvents and membranes. The regenerated resin is recirculated for further use.
    Type: Grant
    Filed: July 31, 2008
    Date of Patent: March 8, 2011
    Assignee: Vale Inco Limited
    Inventor: Flavia Dutra Mendes
  • Patent number: 7641801
    Abstract: A method and system of removing or decreasing waste liquor manganese concentration to less than about 1 mg/L total manganese without the precipitation of significant amounts of magnesium. The method and system include steps for treating the waste liquor using three separate circuits in which in the first circuit, manganese is reduced, for example, from about 2 g/L to <500 mg/L using pH adjustment with a suitable neutralizing agent; and in the second circuit, the final target manganese level is achieved by oxidative precipitation using a suitable oxidizing agent. Part of the precipitated manganese product, e.g., MnO2, is recycled to the oxidative precipitation circuit as seed and the balance proceeds to a third circuit wherein the precipitated manganese product is re-dissolved, and then recycled to the first neutralization circuit. In the first neutralization circuit and the second oxidative precipitation circuit, the process conditions are selected to minimize the precipitation of magnesium, e.g., Mg(OH)2.
    Type: Grant
    Filed: February 28, 2007
    Date of Patent: January 5, 2010
    Assignee: Vale Inco Limited
    Inventors: Mohamed Buarzaiga, Eric Devuyst, Julian Edwards, Joe Paventi
  • Publication number: 20090297709
    Abstract: A method of manufacturing commercial grade, carbon-coated or core-shell type metal powders with highly thermostable characteristics utilizes high-temperature carbonyl decomposition in the presence of carbon monoxide under normal atmospheric conditions.
    Type: Application
    Filed: May 29, 2008
    Publication date: December 3, 2009
    Applicant: VALE INCO LIMITED
    Inventors: ALEXANDRE YOURI ZAITSEV, FRANCISCO ROBINSON, NAM HOAI NGUYEN, VLADMIR PASERIN, CUONG VAN LUONG
  • Publication number: 20090249921
    Abstract: A method for producing metal oxide from a metal salt selected from nickel hydroxide, cobalt hydroxide, mixed nickel-cobalt hydroxide, nickel carbonate, cobalt carbonate, mixed nickel-cobalt carbonate and combinations thereof includes providing a mixture of the metal salt, mixing the metal salt with a binder selected from the group consisting of inorganic binder, organic binder and combinations thereof, forming the mixture into agglomerates, and calcining the agglomerates to produce metal oxide.
    Type: Application
    Filed: April 15, 2009
    Publication date: October 8, 2009
    Applicant: VALE INCO LIMITED
    Inventors: Geoffrey Edwin Osborne, Ahmed Vahed, Samuel Walton Marcuson
  • Publication number: 20090241731
    Abstract: A method for recovering base metal values from oxide ore is provided by the present disclosure. The ore includes a first metal selected from the group consisting at least one of iron and aluminum and a second metal selected from the group consisting of at least one of nickel, cobalt and copper. The method includes the steps of: contacting the oxide ore with hydrogen chloride gas to obtain chlorides of the first and second metals and subjecting at least the first and second metals to pyrohydrolysis at a predetermined temperature to decompose the chlorides of the first metal into oxides. The method also includes the step of mixing the oxides of the first metal and the chlorides of the second metal in an aqueous solution to dissolve the chlorides of the second metal and recovering the dissolved ions of the second metal from the aqueous solution.
    Type: Application
    Filed: August 26, 2008
    Publication date: October 1, 2009
    Applicant: VALE INCO LIMITED
    Inventors: Antonio Clareti Pereira, Flavia Dutra Mendes, Tiago Valentim Berni, Ahmed Vahed
  • Publication number: 20090208405
    Abstract: A method for producing prefluxed metal oxide from a metal salt selected from nickel hydroxide, cobalt hydroxide, mixed nickel-cobalt hydroxide, nickel carbonate, cobalt carbonate, mixed nickel-cobalt carbonate and combinations thereof includes providing a mixture of at least one slag making oxide and a metal salt selected from the group consisting of nickel hydroxide, cobalt hydroxide, mixed nickel-cobalt hydroxide, nickel carbonate, cobalt carbonate, mixed nickel-cobalt carbonate and combinations thereof, blending with a binder, blending in a flux additive to form a slag-making mixture, forming the slag-making mixture into prefluxed agglomerates, and calcining the prefluxed agglomerates to produce a prefluxed metal oxide. An agglomerate is provided which includes a metal salt selected from nickel hydroxide, cobalt hydroxide, mixed nickel-cobalt hydroxide, nickel carbonate, cobalt carbonate, mixed nickel-cobalt carbonate and combinations thereof, a slag making oxide, and a flux additive.
    Type: Application
    Filed: February 6, 2009
    Publication date: August 20, 2009
    Applicant: VALE INCO LIMITED
    Inventors: Geoffrey Edwin Osborne, Ahmed Vahed, Samuel Walton Marcuson
  • Publication number: 20090194747
    Abstract: A method for improving the environmental stability of cathode materials used in lithium-based batteries. Most currently used cathode active materials are acutely sensitive to environmental conditions, e.g. leading to moisture and CO2 pickup, that cause problems for material handling especially during electrode preparation and to gassing during charge and discharge cycles. Binder materials used for making cathodes, such as PVDF and PTFE, are mixed with and/or coated on the cathode materials to improve the environmental sensitivity of the cathode materials.
    Type: Application
    Filed: February 4, 2008
    Publication date: August 6, 2009
    Applicant: VALE INCO LIMITED
    Inventors: Feng Zou, Huan Huang, Lunzhi Liao, Quan Min Yang
  • Publication number: 20090180945
    Abstract: A process for recovering metals such as Ni, Co, Mn, Cu, Zn, among others, through precipitation as sulphides, enabling recovery of magnesium in the form of hydroxide, carbonate and oxide and providing recovery of sulphate as gypsum and ammonium sulphate. Liquid phase, after full treatment, comprises recovered water with a quality proper for total reuse in industrial process. This process of liquid and solid effluent treatment is provided with flexibility to process several types of effluents presenting wide variations in their chemical composition.
    Type: Application
    Filed: January 9, 2009
    Publication date: July 16, 2009
    Applicant: VALE INCO LIMITED
    Inventors: Salomao Solino Evelin, Roberto Mattioli Silva
  • Publication number: 20090087361
    Abstract: A process for producing a purified nickel hydroxide precipitate from a nickel-containing leach solution with impurities including one or more of the following: manganese, copper, zinc, iron and/or cobalt, so that the purified nickel hydroxide is suitable for pelletization with iron-containing ores and/or stainless steel production, includes treating the leach solution with a base to form a slurry of mixed hydroxide precipitate and low-nickel barren solution, thickening the slurry to form filter cake, washing the filter cake and contacting it with acid to dissolve nickel and other metals to produce a concentrated nickel-containing solution, subjecting the concentrated nickel-containing solution to solvent extraction with an organic acid extractant to remove metals other than nickel from the nickel-containing solution and form a solvent extraction raffinate of purified nickel solution and treating the solvent extraction raffinate with a base to precipitate the purified nickel hydroxide precipitate.
    Type: Application
    Filed: September 23, 2008
    Publication date: April 2, 2009
    Applicant: VALE INCO LIMITED
    Inventors: MARC MURRAY RISHEA, Indje Ognianov Mihaylov, Mohamed Buarzaiga, Flavia Dutra Mendes
  • Publication number: 20090056500
    Abstract: A hydrometallurgical resin-in-leach (RIL) process for directly recovering nickel and/or cobalt. Simultaneous pulp leaching by adding an acid or base, dissolves the metals of interest with adsorption of the metals rendered soluble in on ionic exchange resin. Following elution of the changed resin, purification of nickel and cobalt present in the eluate can be recovered by conventional methods, such as precipitation, extraction by solvents and membranes. The regenerated resin is recirculated for further use.
    Type: Application
    Filed: July 31, 2008
    Publication date: March 5, 2009
    Applicant: VALE INCO LIMITED
    Inventor: Flavia Dutra Mendes
  • Publication number: 20090056502
    Abstract: The present invention is related to a hydrometallurgical process to produce nickel as hydroxide, oxide or cathode and produce cobalt preferably as sulfides. The present invention is particularly adequate to process eluate containing nickel and cobalt. Eluates are solutions obtained from elution of ionic exchange resins, loaded (charged) in the RIP (resin-in-pulp) process of ionic exchange, to recover nickel and cobalt from effluent pulps in acid leaching. Following nickel and cobalt recovery in a RIP circuit, they are separated from each other via a continuous ionic exchange process, after which the nickel eluate is formed to produce nickel as nickel oxide by a pyrohydrolysis process.
    Type: Application
    Filed: August 25, 2008
    Publication date: March 5, 2009
    Applicant: VALE INCO LIMITED
    Inventors: Flavia Dutra Mendes, Tiago Valentim Berni
  • Publication number: 20090056501
    Abstract: The present invention refers to a hydro-metallurgical process using resin-in-neutralized-solution in heap leaching effluent. More specifically, the process is applicable to lateritic ore, nickel oxidate, cobalt oxidate or a mixture containing metals of interest—nickel, cobalt and other secondary metals, wherein ore is leached by adding an acid or a base with possible pH adjustment, aided by acid or base with neutralization of heap leaching effluent, by adding lime, limestone, soda or ammonia in the temperature of 70° to 95° C.
    Type: Application
    Filed: August 14, 2008
    Publication date: March 5, 2009
    Applicant: VALE INCO LIMITED
    Inventor: Flavia Dutra Mendes