Resource Efficiency through AI optimised Nickel refining (RETAIN)

The escalating demand for nickel, driven primarily by its critical application in batteries for electric vehicles, underscores the urgent need for more efficient refining methods.

The quantity of high purity nickel entering the marketplace is primarily limited by refining capacity. The complexity of the refining process is further exacerbated by variations in the incoming, partially refined, nickel oxide. This leads to a fall in extraction efficiency and as a result 1000's of tonnes of nickel oxide has to be reprocessed to reach the required level of purity.

Presently, nickel oxide is shipped over 3400 miles from Vale's Clydach plant in South Wales to Vale's Sudbury facility in Canada to be reprocessing using a high-pressure refining technique. If nickel extraction at Clydach could be improved then this would reduce the quantity of reprocessed material , not only increasing the nickel output from the Clydach plant but also releasing capacity at Vale's Sudbury refinery, thus increasing the overall quantity of nickel entering the market place, as well as eliminating the energy consumed, CO2 emissions produced and the costs incurred from the shipping and reprocessing operation.

To address this challenge, the UK-Canada consortium of NTWIST, Vale and Tunley will use their collective expertise to increase nickel extraction efficiency and thereby reduce the material requiring reprocessing by 30%. The project scope involves the integration of advanced artificial intelligence (AI) solutions, designed by NTWIST, into the refining operations at Vale Clydach plant. This will merge AI optimisation capabilities with lifecycle assessment (LCA) insights to facilitate an understanding of the refining process's environmental and operational footprint. The efficacy of the AI tool will undergo rigorous field testing to validate its performance and impact. This project aspires to establish a new industry benchmark for AI in refining, fostering wider adoption and contributing significantly to the sustainability and efficiency of the sector.

By improving nickel production, efficiency, sustainability and promoting UK-Canada collaboration, the project strengthens the UK and Canada's battery and EV production at a time of significant commercial pressure. The innovation, research activity and commercial exploitation, including the potential for IP generation, are evenly shared between the UK and Canada. This partnership underscores a mutual commitment to innovation and sustainability, with far-reaching implications for economic security and environmental stewardship in confronting global challenges.