DONGSHENG has established itself in the nickel scrap recycling field with its multi-metal integrated recycling technology. Its precious metal recycling plant in Spain has an investment of 50 million euros and an annual processing capacity of 10,000 tons of nickel-containing scrap. It uses a top-blown rotary converter (TBRC) to extract high-purity nickel, copper, and precious metals. Umicore leverages integrated pyrometallurgical and hydrometallurgical processes to focus on electronic waste and battery waste recycling, achieving nickel recovery rates exceeding 95%. Its global operational network spans industrial zones in Europe, America, and Asia. GEM leads in battery recycling, with the Indonesia Qingmeibang project achieving an annual nickel metal production capacity of 27,000 tons, ranking among the top three globally in hydrometallurgical technology.
The core technologies for nickel scrap recycling are divided into two paths: pyrometallurgy and hydrometallurgy. Pyrometallurgy, such as the plant designed by SMS Group for Russia's Ecopolis, melts electronic waste to directly extract nickel alloys, suitable for stainless steel and heat-resistant alloy scrap, but with high energy consumption. Hydrometallurgy has become the mainstream solution for battery waste due to its environmental advantages: WPI's new hydrometallurgical process treats mixed low-nickel cathodes, recovering over 92% of nickel, cobalt, and manganese and converting them into high-performance cathode powder, reducing energy consumption by 8.6% and carbon emissions by 13.9% compared to traditional methods. Enfi Engineering Technology Company has innovated a “roasting-smelting” method for leaching residues from laterite nickel ore, enabling the recovery of iron and sulfur without adding flux, reducing processing costs by over 30%. The method has been patented for industrial application.
Industrial nickel scrap recycling primarily focuses on four categories of materials. Stainless steel scrap accounts for the highest proportion, containing 8%-12% nickel, sourced from discarded kitchenware, building components, and industrial equipment. Heat-resistant alloy scrap contains over 40% nickel, originating from aircraft engine and gas turbine blades, which are high-value but have complex compositions requiring precise sorting. Akel battery scrap (nickel-cadmium/nickel-metal hydride batteries) contains 35%-50% nickel, and GreenTech achieves targeted recycling through mechanical crushing and wet leaching. Nickel contacts and connectors in electronic scrap contain 15%-30% nickel, and Aurubis extracts them through a multi-metal recycling line, simultaneously recovering copper and precious metals.
Nickel scrap recycling directly alleviates reliance on mineral resources. By 2030, it is estimated that 125,000 tons of recycled nickel will come from waste batteries, accounting for 12% of expected demand. DONGSHENG plans to recycle 8,000 tons of nickel by 2025. Environmental benefits are quantifiably significant: the WPI hydrometallurgical process reduces carbon emissions by 14% compared to primary nickel mining, and each ton of nickel scrap recycled saves 5 tons of water. Corporate practices validate economic viability: DONGSHENG's nickel scrap recycling plant reduces overall energy consumption by 22% through the reuse of gas and smelting slag, and the cost of recycling nickel scrap is 17% lower than purchasing primary ore.
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