electroplating with carbonyl nickel - sunnball of plating with vale (inco... · 1 plating with...

Electroplating with Carbonyl NickelAugust, 2010

1 Plating with Carbonyl Nickel

Overview:

1. Why carbonyl nickel?

2. What is carbonyl nickel?

3. Advantages of electroplating with carbonyl nickel

4. Disadvantages of electroplating with carbonyl nickel

5. Track record of quality & success

6. Vale carbonyl refineries

7. Business case for electroplating with carbonyl nickel

8. Questions & discussion


Why Carbonyl Nickel?


What is Carbonyl Refining?

Step 1: Step 2:

� Process discovered by Langer & Mond in 1889 (accidentally)

� Pioneered and perfected by Vale (formally Inco) over past century

� Highest purity form of nickel for the most demanding end-use applications

Ludwig Mond


What is Carbonyl Refining:

Step 1: High Pressure Carbonylation

Step 2: Pellet Decomposition


Advantages of electroplating with carbonyl nickel:

� Highest purity nickel

� Convenient size and shape

� Highest packing density

� Highest surface area

� Uniform settling with no bridging in basket

� Conforming baskets

� Automated loading

� Able to mix with other forms of nickel

� Track record of success with high quality electroplating

� Local supply


Highest purity nickel available:

� Carbonyl refining produces the highest purity nickel (99.98 %)

� Minimal carbon and iron impurities

� Trace levels of other impurities

Carbonyl Refining

Impurities don’t carbonylate

Electrolytic Carbonyl

Ni (wt %) 99.91 99.988

As (ppm) 9 <0.01Co 596 <0.2 Pb 1.9 0.02Se 1.3 <0.01 Zn 1.0 <0.2S 1.2 1

Fe (ppm) 5 5 C 24 60

* Q2, 2009, Thompson cathode vs. CCNR pellet

Typical Vale Nickel Plating Grade Purity


Convenient size & shape:

Pellets Chips

� Carbonyl nickel is available in two product forms: pellets & chips

� Both forms are smooth, with no sharp edges, and safe to handle

� These unique product forms impart features important for electroplaters


Highest packing density:

� Carbonyl products have highest packing density

� Uniform current density

� Uniform deposit thickness

� Less frequent replenishing of nickel in baskets

� Less electrical resistance and less power consumption

Effect of Packing Density on Deposit Quality

Anode Deposit

Current

Effect of Packing Densityon Basket Maintenance

LowPD

HighPD

Start

Top-up

ConstantCurrent

4.50

4.75

5.00

5.25

5.50

1x1 P-pellet Chips

Packing Density Comparison

(kg/litre)

Thinner Deposit


Highest surface area:

� Carbonyl products have highest specific surface area (ie. cm2/g)

� Operating voltage decreases with decreasing current density

� Higher surface area reduces power consumption

Pellet/Chip: ∼0.67 cm2/g

Squares: ∼0.33 cm2/g


Uniform settling & no bridging in basket:

� Carbonyl nickel settles uniformly without bridging

� Bridging can effect uniformity of deposit thickness

� Bridging can cause baskets to “burn-out” at nickel voids

� Uniform settling promotes high quality deposits and longer basket life

1x1 Chips P-Pellets


Conforming baskets:

� Carbonyl products are “flowable” and easily conform to shaped baskets

� Maintains constant distance between anode and deposit

� Ensures uniform plating thickness, less power consumption and excellent deposit quality

AnodeDeposit

Standard Basket

AnodeDeposit

Conforming Basket

Thinner Deposit

UniformThickness


Automated loading:

� Carbonyl products are “flowable” and can be fed through automated loading systems

� Reduces labour costs associated with loading baskets

� Easier to maintain optimum nickel level in baskets

� Minimizes nickel losses into tank during basket loading

Sketch of Automated Loading System


Mixing with other forms of nickel:

� Carbonyl products have highest packing density

� Can improve packing density of cut cathode by blending with chips/pellets

� Improves distribution of current density and uniformity of deposit thickness

� Reduces frequency of replenishing nickel in baskets

4x4 4x4/Chips(1)

PD=3.94 kg/l PD=5.28 kg/l

(1) Approximately 2:1 ratio


Disadvantages of electroplating with carbonyl nickel:

1. Carbonyl can produce more residue:

� Minimal economic impact (∼$.0027 /lb)

� No effect on product quality using standard industry practice (bags, filters etc..)

2. Pellets and chips can fall through large or damaged mesh openings:

� Plating chips were designed to minimize issue (ie. similar shape to rounds)

� Good anode bag practice can minimize issue

� Anode baskets can be retrofitted (rather than replaced) to eliminate issue

Chips in Basket

Damaged Basket


Track record of quality & success:

� Carbonyl chips have become a preferred anode material at leading automotive suppliers

� Large plating shops in NA & SE Asia have been using carbonyl chips for years

� End use applications include bumpers, wheel rims and plating-on-plastics (POP)

� Customers appreciate the high quality and ease-of-use of carbonyl products

Union Autoparts Manufacturing (UAM) - Thailand


Track record of quality & success:

� P-pellets are the product of choice for demanding functional applications

Nickel Foam Plant – Dalian, China


Vale Carbonyl Refineries:

� High pressure carbonyl process at Sudbury, Ontario

� Approximately 62,500 tonnes per year (pellet & powder)

Copper Cliff Nickel Refinery (CCNR) – Canada


Vale Carbonyl Refineries:

� Atmospheric pressure carbonyl process at Swansea, Wales

� Approximately 40,500 tonnes per year (pellet & powder)

Clydach Nickel Refinery (CNR) – United Kingdom


Business case for electroplating with carbonyl nickel:

� High quality parts:

- High purity & high packing density with uniform settling

� Low operating costs

- Lower voltage and power consumption

- Easy handling with potential for automated loading

� Proximity to source

- Canadian source

� Track record of success

- Being used by leading electroplaters globally

� Technical support

- Able to provide technical support for trials etc…

� Competitive price

- Discount to accommodate introduction of new product


Questions & Discussion

electroplating with carbonyl nickel - sunnball of plating with vale (inco... · 1 plating with...

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