Crystallization of nickel sulfate and its purification process: towards efficient production of nickel-rich cathode materials for lithium-ion batteries

NiSO(4)·6H(2)O is an important salt for the battery-making industry. The extraction of nickel sulfate relies on the hydrometallurgical processing of nickel ores as well as the recycling of nickel-containing products. The last step in hydrometallurgical processing is the crystallization of nickel sulfate. Because of the similar ionic radius and ionic charge between nickel and magnesium ions, magnesium undergoes isomorphous substitution and replaces nickel ions in the crystal lattice structure of NiSO(4)·6H(2)O. This poses a challenge as achieving the desired metal salt purity is difficult, resulting in an inferior cathode material for nickel-containing batteries. In this work, the removal of magnesium during the purification process of NiSO(4)·6H(2)O crystals via a repulping process was thoroughly investigated. Moreover, the impurity uptake mechanisms of magnesium into NiSO(4)·6H(2)O crystals were investigated. The results indicated that repulping NiSO(4)·6H(2)O crystals with a saturated NiSO(4) solution results in 77% removal of magnesium. Using a second-stage repulping process is less effective with only 26% magnesium removal. The purification efficiency of the two repulping stages was quantified by the equilibrium distribution coefficient, which corroborates the trend of decreased removal of magnesium in the second stage of repulping compared with the first stage. The primary impurity uptake mechanisms of magnesium into NiSO(4)·6H(2)O crystals were identified to be surface adsorption and lattice substitution (isomorphous substitution).