top of page

Our Process

Westwin transforms nickel intermediate into Class 1 metal products (nickel powder & nickel briquettes) through a multi-step process. The process begins with the input of intermediates such as mixed hydroxide precipitates (MHP), high-grade nickel matte (HGNM), or black mass into a feed preparation circuit. The material then goes through a carbonyl circuit, where impure nickel is vaporized as part of the refining process. High-purity nickel powder and nickel briquettes are produced post refinement and decomposition within the carbonyl circuit. Class 1 metal products can also be transferred to a hydrometallurgical dissolution circuit to produce nickel sulfate. 

Carbonyl Process Graphic

* HGNM requires roasting pretreatment.

** Pre-feasibility studies for the integration of the dissolution circuit have been completed, yet the inclusion of a nickel sulfate circuit is subject to market demand.

Carbonyl Overview

The carbonyl process, developed in 1890, and commercialized in 1902 by Mond refines metals by vaporizing them under high pressure with carbon monoxide (CO), enabling their purification and extraction from various feed materials. This method stands out for producing high-purity metals efficiently and sustainably, with lower energy consumption and waste compared to pyrometallurgy, which relies on high-temperature processes like smelting or roasting, and hydrometallurgy, which uses aqueous solutions and chemical reactions for metal refinement.

Dissolution Overview

Nickel dissolution is the process of breaking down solid nickel into a liquid solution, typically using acids like sulfuric acid to produce battery grade nickel sulfate. Advanced dissolution methods aim to maximize nickel recovery while minimizing waste production. By carefully controlling reaction conditions and optimizing acid usage, waste levels can be significantly reduced, supporting more sustainable and environmentally friendly practices.

Competitive Advantages

First-Mover Advantage

Westwin Elements is uniquely positioned as the first major nickel refinery in the U.S., therefore securing a critical role in reshoring the supply chain to meet the growing demand for American-made nickel products. 

Proven Technology & Expertise 

Carbonyl processing technology has been reliably used for over a century. Westwin’s technical leadership team boasts over 250 years of combined experience, ensuring reliability and operational efficiency. 

Environmental Sustainability

The carbonyl process is the most environmentally sustainable metallurgical method, producing zero liquid or solid waste streams.

Future-Proof & Circular Design

Westwin’s plant is designed for modularity and versatility, capable of producing a wide range of products and processing various feedstocks, including recycled materials, to support a circular economy.

High Purity & Customization

Carbonyl processing enables the production of Class 1 nickel (≥ 99.9%). Westwin products can be tailored to meet specific customer requirements for stainless steel, aerospace and defense, EV batteries, and other market applications.

bottom of page