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An acid-free process to prepare battery grade nickel and cobalt sulfates from complex resources

Author

Listed:
  • Qing Zhang

    (University of Chinese Academy of Sciences
    Chinese Academy of Sciences
    Chinese Academy of Sciences)

  • Xiaohong Zheng

    (Chinese Academy of Sciences
    Chinese Academy of Sciences
    China University of Geosciences (Beijing))

  • Weiguang Lv

    (Chinese Academy of Sciences
    Chinese Academy of Sciences)

  • Mingming He

    (Chinese Academy of Sciences)

  • Wenyi Yan

    (Chinese Academy of Sciences
    Chinese Academy of Sciences)

  • Wenfang Gao

    (Hebei University of Technology)

  • Pengge Ning

    (Chinese Academy of Sciences
    Chinese Academy of Sciences)

  • Hongbin Cao

    (University of Chinese Academy of Sciences
    Chinese Academy of Sciences
    Chinese Academy of Sciences)

  • Zhi Sun

    (University of Chinese Academy of Sciences
    Chinese Academy of Sciences
    Chinese Academy of Sciences)

Abstract

Nickel sulfate is a critical compound for lithium-ion batteries, mainly prepared from nickel sulfide concentrate (NSC). Typically, high-temperature smelting or high-pressure leaching is required to achieve high extraction rates for Ni and Co. Here, we demonstrate an acid-free atmospheric leaching process for effectively processing of NSC using a mechanochemical treatment. When a suitable intermediate phase of the NSC is obtained, the leaching efficiency for Ni and Co can reach 97.4% and 98.8%, respectively, while the main impure element, iron, almost remains in the solid phase. As a consequence, the leaching solution can be easily treated to prepare battery-grade NiSO4. A technoeconomic analysis demonstrates that the acid-free process provides excellent economic advantages, with carbon emissions being reduced by 59.5%. This provides a sustainable alternative for processing complex sulfide resources and is expected to be applied to zinc and copper sulfide concentrates.

Suggested Citation

  • Qing Zhang & Xiaohong Zheng & Weiguang Lv & Mingming He & Wenyi Yan & Wenfang Gao & Pengge Ning & Hongbin Cao & Zhi Sun, 2025. "An acid-free process to prepare battery grade nickel and cobalt sulfates from complex resources," Nature Communications, Nature, vol. 16(1), pages 1-11, December.
    • Handle: RePEc:nat:natcom:v:16:y:2025:i:1:d:10.1038_s41467-025-59995-6
    DOI: 10.1038/s41467-025-59995-6
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    References listed on IDEAS

    as
    1. Schmidt, Tobias & Buchert, Matthias & Schebek, Liselotte, 2016. "Investigation of the primary production routes of nickel and cobalt products used for Li-ion batteries," Resources, Conservation & Recycling, Elsevier, vol. 112(C), pages 107-122.
    2. Hailong Li & Jiaoqin Zheng & Wei Zheng & Hongxiao Zu & Hongmei Chen & Jianping Yang & Wenqi Qu & Lijian Leng & Yong Feng & Zequn Yang, 2023. "In situ acid etching boosts mercury accommodation capacities of transition metal sulfides," Nature Communications, Nature, vol. 14(1), pages 1-13, December.
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