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Transcript of nickel Ore
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Nickel Ore ProcessingPrepared By- Mukesh Ranjan Behera
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CONTENTS- What is Nickel Nickel Physical and Chemical Properties Nickel History and Indian Nickel Market Formation of Nickel and its Types Processing Options relative to deposit type Laterite Ore Processing Sulfide Ore Processing Sukinda COB Analysis World Nickel Reserve and Production Nickel Uses
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WHAT IS NICKEL- Nickel is a strong, lustrous, silvery-white metal. Nickel is a chemical element with symbol Ni and Atomic number
28, atomic mass 58 amu (one nickel atom contains 28 protons, 28 electrons, and 30–36 neutrons depending on the isotope).
Isotopes: Five stable isotopes: Nickel-58, nickel-60, nickel-62, nickel-61, nickel-64.
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Nickel
Crystal of Nickel Face-centered cubic(FCC) structure. In fact, about 65 per cent of nickel is used to manufacture stainless steels, and 20 per cent in other steel and non-ferrous (including "super") alloys, often for highly specialized industrial, aerospace and military application.The most common ores of Nickel include Pentaldite, Pyrrhotite, Garnierite.
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NICKEL PHYSICAL PROPERTIES Color-Silvery White Metal Phase-Solid Melting Point-1455 degree centigrade Boiling Point-2730 degree centigrade Density- 7.81 g/cm3
Conductivity- Fairly good conductor of heat and electricity Malleability- It’s capable of being shaped or bent Luster- Exhibits a shine or glow Hardness- Harder than iron Ferromagnetic- Nickel is easily magnetized Ductility- It can be beaten into extremely thin sheets. It is more resistant corrosion and oxidation.
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CHEMICAL PROPERTIES- Nickel is relatively un reactive, but react with strong acids. It does not react with alkalis.
Nickel History-The elements name come from German mythology, Nickel. In 1824 People thought that Nickel as a by product of cobalt. The introduction of nickel in steel production 1889 was increased because the demand of nickel increased.The main deposits in world are New Caledonia in Pacific,Sudbury Region in Canada, and Norilsk in Russia.In 1922 -1981 Canada is the largest Nickel Producer in World.In that time Canada use 99.9% of nickel, in coin producing.Nickel Occurs nature Principally as Oxides, Sulphides, and Silicates.Ores of Nickel are mined in Over 23 Countries and are smelted or refined in 25 Contries.
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Indian nickel market India does not have any history related to the metal nickel.In India nickel is vary law grade deposit and there is no processing plant. But as one of the fastest developing nations of the world, Indian demand for stainless steel and consequently nickel has been rising at a high rate.A rising demand and no production makes the country a total importer of nickel. The country imports around 50000 MT of nickel annually. This demand is expected to rise in future with the increase in the demand of stainless steel. The government has implied import duties in the import of the metal @ 15%.
Primary nickel is produced and used in the form of Ferro-nickel, nickel oxides and other chemicals, and as more or less pure nickel metal. Nickel is also readily recycled from many of its applications, and large tonnages of secondary or "scrap" nickel are used to supplement newly mined metal
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FORMATION OF NICKEL ORE- Pure nickel shows a significant chemical activity that can
be observed when nickel is powdered to maximize the exposed surface area on which reactions can occur.
Even then, nickel is reactive enough with oxygen that native nickel is rarely found on Earth's surface, being mostly confined to the interiors of larger nickel–iron.
On Earth, such native nickel is found in combination with iron, Earth's inner core.
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Primary nickel is produced from two very different Ores 1. Laterites 2. SulphidesLaterites ores are normally found in tropical climates where weathering, with time, extracts and deposits the ore in layers at varying depths below the surface. Laterites ores are excavated using large earth-moving equipment and are screened to remove boulders. Sulphides ores, found in conjunction with copper-bearing ores, are mined from underground..
Laterite Ore SulphidesOre
Characterestics of ore
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CLASSIFICATION OF NICKEL LATERITES ORE-A: Hydrous Mg-Ni silicate deposits (~35% of total resource) serpentines, Nepouite, Garnierite in saprolite High grade: global mean 1.53% Ni
B: Semecite silicate deposits (~15% of total resource) Clays content with saprolite and pedolith Low grade: global mean 1.21% Ni
C: Oxide deposits (~50% of total resource) Fe and minor Mn oxides, in form of saprolite and pedolith Low grade: global mean 1.06% Ni
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Laterites include limonites, saprolites and their mixtures (laterites contain max. 3-4% Ni). Limonite reserves are greater than saprolites.About 35-40% of world primary nickel production comes from laterites( but difficult processing, upgrading, high capital and operating cost compared to Sulphides).
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East Pinares, Cuba, Oxide Goro New Caldonia,Oxide CAWSE Western Australia ,Oxide
PLATEUA,New Caledonia,Silicate
Murrin Murrin Australia
Hydrous Silicate
Bulong Western Australia Semisite Silicate
CIRCE New Caldonia Hydrous Silicate
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Lateritic Ore Processing Nickel laterite is a complex ore containing several kinds of
metal elements. Nickel present as a minor constituents of other minerals, therefore, it is not easy to concentration.
Lateritic ores have a high percentage of free and combined moisture, which must be removed.
Drying removes free moisture; chemically bound water is removed by a reduction furnace, which also reduces the nickel oxide.
Ni atoms
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PROCESS ORE PRODUCT COMMENTSmelting1859, New Caledonia
Hydrous silicate Ferro-nickelmatte
Energy intensive; (smelting ~1600ºC)
Caron processReduction & ammoniacal leach1944, Cuba
Oxide; hydrous silicate
Ni oxide; Ni briquettes Energy intensive (reduction ~700ºC) low Co recovery
High pressure acid leach (HPAL)1959, Moa Bay, Cuba
Oxide; smectite Ni briquettes; electronickel; oxide, sulphide, carbonate
Less energy intensive. Plant & process problems
Atmospheric Leaching
Hydrous silicate Ni-Co hydroxide Atmospheric leach after HPAL
Acid heap leach H2SO4 Atmospheric leachH2SO4 HCl/MgCl2
Oxide; smectite
Oxide; smectitehydrous silicate
Ni-Co hydroxide Lower capital cost;Lower recoveries
PROCESSING OPTIONS FOR NICKEL LATERITES-
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PROCESSING OPTIONS RELATIVE TO DEPOSIT TYPE
Oxide(or smectite)
Transition
Hydrous silicate
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Hydrous silicate ore(“garnierite”; serpentine)Too costly for smectite
e.g., tumbling of boulder ore
1400 - >1600ºC; high energy cost
SiO2/MgO <2 or >2.5= ferronickel
SiO2/MgO 1.8-2.2= matte
~77% of total production in 2000 33% or less of new capacity NICKEL LATERITE PROCESSING
Smelting
FEED
P ROCEESS
Drying
Upgrading
Reduction roast
Smelting
Converting
P RODUCT
Fe-Ni or Ni matte90% recovery
Ni: >2.0%Co: 0.04%Fe: 20%MgO: 25%
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High grade oxide ore, some hydrous silicate; tolerates more Mg than HPAL. Too costly for smectite.
~700ºC; high energy cost
Complex pyrometallurgical - hydrometallurgical process; high energy cost with lower recoveries than smelting and PAL.
No new plants anticipated
NICKEL LATERITE PROCESSINGCaron process
FEED
P ROCEESS
Reduction roast
Grinding, drying
Leach ammonia cal CO3
Cobalt separationNi carbonate precipitation
P RODUCT
Ni:94% recovery
Ni: 1.8%Co: 0.1%Fe: 25-40%MgO: <12.0%
Co:90% recovery
Calcining
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Oxide or smectite ore, low Mg and Al to reduce acid consumption
Upgrade oxide by screening to remove barren silica
High capital costs, with new plants having numerous teething problems in plant and process.
Product options include sulphides: Murrin2, Halmahera hydroxide: Ravensthorpe, Vermelhocarbonate: Cawse
NICKEL LATERITE PROCESSING
High pressure acid leaching
FEED
P ROCEESS
Leach H2SO4
Ore preparation
Acid plant
S
Energy
Wash/neutralizeSX-EW or precipitate
P RODUCT
Ni:94% recovery
Ni: 1.3%Co: 0.13%MgO: <5.0%
Co:90% recovery
240-270ºC; lower energy cost Caron process
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NICKEL LATERITE PROCESSINGAtmospheric leaching
FEED
Oxide ore (but, potentially, any ore type, including low grade hydrous silicate)
P ROCEESS
Heat and leach H2SO4
Ore preparation
Acid plant or excess from HPAL
S
EnergyWash/neutralize
SX-EW or precipitate
P RODUCT
Ni (Co) hydroxide~80-90% recovery
Ravensthorpe, Gag Island: oxide, serpentine saprolite (hydrous silicate)Sechol: oxide, saprolite
Enhanced high pressure acid leaching (EPAL); 80-105ºC
Sechol/Jaguar tested HCl/MgCl2 leach at 80-105ºC. Process could also yield MgO and magnetite concentrate as products. Trial discontinued
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NICKEL LATERITE PROCESSINGHeap leaching
FEED
Potentially, any ore type, including low grade hydrous silicate and rejects
P ROCEESS
Heap, leach for 12-18 months
Ore preparation
Acid plant or excess from HPAL
S
EnergyWash/neutralize
P RODUCT
Ni (Co) hydroxide ~80% recovery
SX-EW or precipitate
Caldag, Nornico - oxide; Murrin Murrin - smectite
Crush; upgrade by screening to remove barren silica
Neutralize using low grade saprolite ore
Suitable for smaller deposits; low capex and opex
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PROCESSING OPTIONS FOR NICKEL LATERITES
HPAL Atmospheric leach
Heap leach
Capital expenditure $17-22 $13-16 $8-12
Operating expenditure $2.50 $2.50 $2.50
$US/lb Ni
Traditional processing (smelting, Caron) is generally very energy intensive. HPAL plants use less energy but require high capital expenditure and are yet to be fully optimized best suited to large deposits. Acid leaching at lower temperatures and ambient pressures offer lower capital expenditure (but lower recovery). Better mineralogical characterization is needed to optimize grade control, beneficiation and processing.
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FERRO NICKEL ORE-
A recent development in the extraction of nickel laterite ores is a particular grade of tropical deposits, typified by examples at Acoje in the Philippines.
This ore is so rich in limonite (generally grading 47% to 59% iron, 0.8 to 1.5% nickel and trace cobalt) that it is essentially similar to low-grade iron ore.
Fe –Ni Ores Processing-
1. Pyro-metallurgy(Rk-EF-75%)2. Hydro-metallurgy(HPAL-15%) 3. Combined(Caron Process, Rather Obsolete) 4. Nickel Smelting Technology
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Nickel Project Owner Country % Ni KT Ni Process
Cerro matoso BHP-B Colombia 2.3 41.6 RKEF
Codemin Anglo Brazil 2.1 9.1 RKEF
Doniambo SLN/Eramet New Caledonia 2 51.1 RKEF
Falcondo Falcon Bridge Dominican Rip 1.14 18.8 RKEF
Larymna Larco SA Greece 1.10 19 RKEF
Loma d NIquel Anglo Venezulea 1.6 10.9 RKEF
Pomala PT ANTAM Indonesia 1.58 17.6 RKEF
Kavadarci Cunico F.Y.R.O.M 2 15 RKEF
Sorowako Vale Inco Indonesia 2.10 72.4 RKEF
Murrin Murrin Mineral Resources Australia 1.43 30.5Moa Bay Cuba 1.5 31.5
Fe –Nickel Production in world-
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FE –NI PRODUCTION IN GREECE- Larco is the Fe-Ni producer in Europe. 13th Largest Nickel
production in world. Covers more than 6% of the annual demand in Europe. Ni production is 19000 tons per year(Avg Ni content Fe-Ni 20%).
Laterite ore Production in Greece(tonnes)-
2010 2011 2012 2013 Total Production
2200000 2600000 2300000 2200000 85000000
Mines Annual Production(tonnes)
Average Ni Content (%)
Evia Mine 1.2-1.5 million 1-1.03
Ag. Ioannis mine 700,00 1.05-1.1
Kastoria Mine 250,000-300,000 1.3
Servia Lignite mine 350,000 1.2
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KEY FACTS OF RESOURCES-
Sample Evia mine(55% w/w) Ag . Ioannis mine(30% w/w)
Kastoria mine(15% w/w)
SiO2 28.2 18.6 32.2
Al2O3 7 10.9 2.9
Fe2O3 47.5 45 24.8
Fe Total 33.2 31.4 7.2
Cr2O3 3.1 2.7 1.4
MnO 0.04 0.04 0.01
MgO 3.2 4 15.4
Ni 1.03 1.05 1.3
Co 0.05 0.06 0.06
S 0.4 0.45 0.45
Cao 3 6.6 1.45
LOI 5 7.5 12.5
Mineralogical and chemical composition of Larco Laterite Ores(% wt)
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Fe-Ni Production Process
Handling Of Raw Materials
Pre-heating and Pre Reduction in Rotary Kilns
Electric Furnace Reductive Smelting
Enrichment-Refining in OBM type Converters
Fe Ni SpecificationsChemical Element Content
Ni 17-25%Co 0.75-1.00%As 0.15% maxP 0.02% maxS 0.15% maxCu 0.10% maxC,Mn,Si,Cr Traces
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Flow Chart of FeNi Production in Larco
Oxygen Bottom Maxhuette-Oxgen bottom Blow Process
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Material and Energy supply (Disel,electricity,electrodes,coke,Pellet,etc)
Waste Management Utilization
Field Operations
•Ore Mining and Beneficiation
Plant Operations
•Feed Operation
Plant Operations
•Smelting and Refining
Rotary Kilns
EF Furnace OBM Converter
Raw Materials Stockpiles
PelletDust Collector
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Stage Input Unit
Value
Ore Mining and Mineral Beneficiation
Electricity
Disel
kWh/t ore Litre/t ore
4.8
2.4
Ore preparation Electricity
Cement
kWh/t ore
T/t Fe Ni
21.8
0.25
Smelting and Refining
Lignite
Coal
Carbon Electrodes Lime
Oxygen
Electricity
T/t Fe Ni
T/t Fe Ni
Kg/t Fe Ni
Kg/t Fe Ni
Litre/t Fe Ni
kWh/t Fe Ni
2.84
2.63
63
74
210
10286
Input Inventory Data-
Functional Unit: 1 t of FeNi product (20% Ni)
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THE EFFECT OF GANGUE MINERALOGY ON THE DENSITY SEPARATION OF LOW GRADE NICKEL ORE
Density separation is widely used to pre concentrate minerals and reject unwanted gangue. For base metal sulfide ores, dense medium separation(DMS) is used to separate the sulfide minerals, which are relatively dense.
After DMS it is treated in Flotation . Overall upgrade of Ni from 0.4 to 0.7% Ni in the flotation sample as a recovery of 87%.
The efficiency of DMS according to the characteristics of the ore .For low grade ores with complex mineralogy, the properties of the gangue minerals are important factor that determine the behavior of the ore during the separation.
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The sink-float analysis results on the head sample indicate that, at a density cut-point of 3.0, 48 mass % of the ore reported to the sinks and 52% to the floats(Figure-1) . For Pentaldite Ore
Figure 1 Washability curve
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The Ni grade was measured at 0.4% and the cumulative grade achieved at Pentalandite a cut-point SG of 3.0 is 0.74% at a recovery of 83%. This density cut-point was chosen for the DMS test work in order to maximise the waste rejection while obtaining a low Ni grade in the overflow(Figure-2) .
Figure 2 Cumulative grade and recovery curves calculated for pyrrhotite and pentlandite from the sink-float analysis
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In Nkomati mine where initial mining activity was centered on the Ore. More recently the mining has been focused on lower grades ores. Average Ni and Cu ores grade are 0.66 to 0.68% and 0.22 to 0.44% respectively.
The flow sheet of Nickel Production. A pentlandite grade of approximately 2% should be present in
the underflow, with a recovery of 83%. The pyrrhotite grade is estimated at 12%, with an 88% recovery.
Grinding 300 micron
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DMS TEST WORK AT A CUT POINT OF 3The nickel Grade and Recoveries, as well as mass distribution of the bulk sample calculated
Stream No Stream Name
Mass(%) Ni Grade(%)
Ni Recovery (%)
1 ROM 100 0.43 1002 -12mm+1mm 84 0.39 763 -1mm 16 0.62 244 DMC
Overflow44 0.13 13
5 DMC Underflow
50 0.67 63
6 Flotation feed
46 0.67 87
Mass,Grde,Recovery Information at different Point of the Flow Sheet-
Fraction Mass(%) Grade (%) Recovery( %)SSs Cc
Sinks 48 5.63 0.23 0.67 85 68 83Float 52 0.95 0.10 0.13 15 32 17Total Feed
100 3.20 0.16 0.39 100 100 100
S Cu Ni NiCuS
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Nickel Resources
Source Ni Fe Cu SiO2 Al2O3 MgO Others
Nickel FerrousSerpentine
MoreahAssam
0.51 7.86 ------ 33.84 ----- 33.14 --------
Do RanakpurRajasthan
0.26 5.75 38.45 1.83 37.18 16.19LOI
Nickel FerrousLaterite
BadampharOdisha
0.34 29.4 15.5 22.4 3.4 Cr2O30,27 V2O5
Do (Dense) SukindaOdisha
0.62 39.5 0.02 16.5 14 1.2 1.85Mn
Do(light) SukindaOdisha
1.41 47.04 6.8 12.36 1.1 2.9 MnO
CopperTailings
I.C.C.Ghatsila
0.073 9.33 0.17 59.7 13.94 ------- 1.45 S1.27 P2O5
Nickel Resources and Their Chemical Analysis in India-
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Sukinda Chromites Over Burden Analysis By NML-The average nickel concentration in the COB ore of Sukinda lies in the range of 0.4-0.7%. The existing deposit of COB ore in the Sukinda valley has been estimated to he around 140 million tonnes.
Process for Nickel Enrichment- COB ore of Sukinda valley is a high silica matrix. Present nickel enrichment process consists of primarily three stages.
Neutralisation
Stage I : Digestion with acid/ Combination of acids, HCI, HNO3 and H2SO4.Stage lI Neutralisation with alkali. Na2CO3 and NaOH.Stage III : Calcination at 900°C
Oxides of Ni,Co,Cr,Fe
Hydroxides of NiCo,Cr, and Fe
Leach liquor of Ni,Co,Cr, and FeRaw Nickel Ore
Ni-0.4-0.7%I
Digestion
II
III Calcination 900 degree centigrade
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Parameters Optimized Value
COB ore 500 mg
Fineness -44 mesh
Hcl Concentration 50ml 12N
HNO3 Concentration 50 ml 14 N
H2SO4 Concentration 100 ml 36 N
H20 500 ml
Digestion time 3 hr
Temperature 100 degree Centigrade
Optimized Parameter with reference to extraction of Nickel-
Final product :-The final product after the calcination was essentially a mixed oxide of Fe, Ni, Cr, Co and other trace elements like, Al, Mn,Zn, Na. Ca etc. Complete analysis of a typical final product is given in Table .
Element/Radical Content(%)
LOI 0.11
SiO2 0.13
Fe2O3 92.12
NiO 2.54
Cr2O3 1.75
CoO 0.14
Al2O3 1.21
MnO 1.42
ZnO 0.38
Na2O 0.67X-ray diffraction of the final product indicated that it consisted of two phases Fe2O3and nickel ferrite,NiFe2O4. It could be possible that the final product consisted of a magnetic and a non magnetic phase
Complete Analysis Of Final Product-
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Fe2O3 constituted the nonmagnetic fraction while NiFe2O4 made for the magnetic fraction. This opened up the possibility of further nickel enrichment by separating the magnetic and non-magnetic fraction through magnetic separation. It was calculated from chemical analysis assuming all the nickel were converted into NiFe2O4 the percentage is 9.37% . The process is not energy intensive and generates valuable by-products that have ready market in the country. The process is environment friendly and does not waste and effluent disposal problems.
Sukinda Chromite Ore Mines
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30
15
117
7
6
5
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4 2 2 2
World Nickel ReserveAusraliaNew CaledoniaBrazilRusiaCubaOtherIndonesiaSouth AfricaCanadaChinaMadagascarPhilipinesDominan Republic
422007 2008 2009 2010 2011 20120
100
200
300
400
500
600
700
800
Africa
Asia
Oceania
America
Europe
Global Nickel Production in MT
43
34
20
13
7
7
5
55
1.2
Nickel Uses in Different SectorTransport/Defence
Fabricated Metal
Electric Equipment
Petroleum Industry
Chemical Industry
Construction
household Ap-pliances
Industrial Ma-chinery
Other
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653.90.8
7.3
8.3 5.3
2.72.9
0.5 0.92.4
Estimate Use of Nickel 2014Stainless steel
Super alloys
Coinage
Other nickel alloy
Plating
Other steel alloys
Foundry
Batteries
Catalyst
Other Chemical
Other
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Nickel Uses
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