Esperance Ni Sulphate Plant

The Esperance Project

– Information for the community

Alpha Fine Chemicals (AFC) is proposing to construct and operate a nickel sulphate plant at Esperance in the south east of Western Australia. Using new technology that is simpler, safer and less expensive than existing methods, the Esperance Nickel Sulphate Plant will produce 20,000 tonnes per annum of high purity nickel sulphate crystals to supply the lithium-ion battery market for electric vehicles and stationary storage.

Subject to normal local and state government approvals our first plant will be strategically located only a few kilometres from Esperance Port and therefore access to markets and raw materials.

This facility is expected to provide at least 50 full time jobs and will operate for 20 years.

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Esperance Nickel Sulphate Plant

AFC has completed a pre-feasibility study into building a nickel sulphate plant at Esperance, Western Australia. The plant will produce 20,000 tonnes per annum of high purity nickel sulphate in crystal form together with valuable co-products in cobalt carbonate and magnesium sulphate.

The pre-feasibility study is underpinned by an extensive test work program which culminated in two separate 12 hour continuous campaigns on the CMN Process mini pilot rig. Assays of the nickel sulphate produced by AFC in the study confirm the high purity status of AFC’s product.

The feed for the plant will be mixed hydroxide precipitate (MHP). AFC’s intention is for the plant to operate on third party feed.

The project is now in the definitive feasibility study phase.

Project Background

AFC holds certain exclusive rights to the CMN Process technology.  The CMN Process is patented solvent extraction technology developed by one of AFC’s key partners, Canopean Pty Ltd. AFC investigated a number of potential project applications for the CMN Process before settling on the Esperance nickel sulphate plant to produce 20,000 tpa of high purity nickel sulphate to support the growing demand from the battery and plating sectors.  Research completed on behalf of AFC by Lux Research concluded that nickel consumption in lithium-ion batteries for electric vehicles and stationary storage units are projected to increase by 1,200% over the next 10 years.

Project Location

Options for locating the plant near Esperance are currently being assessed. AFC will continue to work with local stakeholders to identify potential sites based on zoning, size, compatibility with surrounding land uses, access to transport routes and proximity to the port.

Technology

The CMN Process is solvent extraction technology which, due to some key patented steps, facilitates the production of high purity end products.  The CMN Process does not involve any complex process operations or toxic and/or flammable gases.  These attributes together with the use of field proven, cheap, readily available and stable reagents results in a plant that is easier and simpler to operate with significant savings in operating and capital costs compared to alternative processes.

Nickel sulphate on the left (the end product) and mixed hydroxide precipitate (the plant feed) on the right.

Product 

A key benefit of the patented purification steps in the CMN Process is that AFC can produce a nickel sulphate hexahydrate product to meet the most demanding of specification requirements. As a new business, AFC now has the opportunity to work with end users on an exclusive basis to produce a product to meet their specific requirements in terms of impurity levels, crystal size and packaging. AFC has produced advance electrolyte from two continuous campaigns on a mini pilot plant. Using this advance electrolyte and with the controlled addition of sulphuric acid and cooling, AFC has produced its first batch of nickel sulphate crystals with the following specifications:

Typical Analysis

Element	Specification
Ni	22.28 %
Al	<0.0005%
Ca	0.0005%
Co	0.0005%
Cu	<0.0005%
Fe	<0.0005%
Mg	0.0005%
Mn	<0.0005%
Zn	<0.0005%

It should be noted that these specifications were achieved with the mini pilot rig essentially on ‘set and forget’ mode with no real capacity to make adjustments to the plant during the run.  Consequently, AFC is very confident that future specifications will exceed these.

Packaging 

The nickel sulphate crystals will be packaged into double lined one tonne bags before loading into containers for shipment to customers.