How extracting and producing nickel can be made more sustainable
Manzoor, U., Mujica Roncery, L., Raabe, D. et al, 'Sustainable nickel enabled by hydrogen-based reduction', Nature 641, 365–373 (2025). doi.org/10.1038/s41586-025-08901-7
Nickel powers everything, from gadgets to green technologies. But getting it currently involves a far from green, in fact, a dirty process. However, a new study has revealed what its authors have said is a game-changing and sustainable method to extract nickel from low-grade ores using hydrogen plasma instead of carbon. It's a one-step process free of carbon dioxide that reportedly saves both energy and time.
Nickel is an important metal used in several clean energy technologies, especially Electric Vehicles (EVs), and the demand for it is expected to surpass six million tonnes a year by 2040. While EVs are seen as a cleaner alternative to traditional fossil fuel-powered vehicles, there are hidden environmental costs associated with their production, especially in the manufacturing of lithium-ion batteries.
A major component in these batteries is nickel and its extraction is highly carbon-intensive. Producing just one tonne of nickel can result in more than 20 tonnes of carbon dioxide emissions. So while EVs reduce emissions during operation, the process of sourcing materials like nickel simply shifts the pollution burden from the transportation sector to the mining and processing sector, among others.
The methodology
The study, published in Nature on April 30, was conducted by researchers at the Max Planck Institute for Sustainable Materials in Düsseldorf, Germany. In the study, the researchers bypassed the traditional multistep process to extract nickel — which includes calcination, smelting, reduction, and refining — and developed a single metallurgical step conducted in one furnace. 'The proposed method has the potential to be up to about 18% more energy efficient while cutting direct carbon dioxide emissions by up to 84% compared with the current practice,' the paper wrote.
Ubaid Manzoor, a researcher at the Max Planck Institute and lead author of the study, said, 'Traditional nickel extraction is multi-step, energy-intensive and relies on carbon. Nickel oxide is heated with carbon, which removes the oxygen, producing pure nickel, along with carbon dioxide emissions.' The researchers have proposed replacing carbon with hydrogen as the reducing agent and using electricity as the energy source, specifically through an electric arc furnace.
'In our method, we use hydrogen plasma. Hydrogen gas, when subjected to high-energy electrons in an electric arc, splits into high-energy ions, entering a plasma state — the extremely hot and reactive fourth state of matter. It is distinct from solids, liquids, and gases. This hydrogen plasma rapidly reduces the metal oxides. From a thermodynamic perspective, the process is not only cleaner but significantly faster,' Mr. Manzoor said. He added that the method is kinetically superior — meaning the chemical reaction is more energetically favoured — thanks to the highly reactive and unstable nature of plasma.
'The end product of hydrogen reacting with oxygen is water, not carbon dioxide. Therefore, the entire process is carbon-free, using only electricity, hydrogen, and yielding water as a byproduct,' he added.
Enabling sustainable production
The study focused on laterite ores, a type of soil-rich rocks that contain metals like nickel. They form in hot, tropical regions when rain and heat break down rocks over time, leaving behind metal-rich layers. They are abundant but tough to process. 'While sulphide ores are found deeper underground and are easier to process, they're rapidly depleting. The new method used in the study works efficiently on laterites, making it key to future nickel production,' Mr. Manzoor said.
India has substantial nickel laterite reserves, particularly in Odisha's Sukinda region. 'These deposits, containing 0.4-0.9% nickel as nickeliferous limonite in chromite mine overburden, are often overlooked because traditional methods require higher-grade ores. But [the team's method] excels at extracting value from these lower-grade resources,' Dierk Raabe, professor and director of the Max Planck Institute and co-author of the study, said. He added that the technology could play a major role as the demand for sustainably produced materials continues to grow.
'Without such innovations, the sustainability revolution — whether in electrification, renewables, or green infrastructure — risks merely shifting the carbon dioxide and energy burdens from one sector to another. In other words, we might build a 'greener' world through EVs, solar panels, and high-performance magnets while still relying on carbon-intensive methods to mine and refine the critical metals … that make all of it possible,' he said.
The inescapable demand for nickel in multiple industries and its traditionally carbon-intensive production pose 'a particular challenge for countries like India, where rapid industrial growth is essential for economic development. India must simultaneously meet ambitious climate goals and leverage market opportunities in the green economy,' Mr. Raabe added.
He continued that the technology aligns well with India's dual goals — to accelerate industrialisation and infrastructure development while staying committed to the goal of achieving net-zero emissions by 2070. It also reduces the need to import high-grade ores and maximises the potential of domestic, underutilised mineral assets, he added.
Some challenges
Pratik Kumar, assistant professor in the Department of Civil Engineering at IIT-Jammu and who wasn't associated with the new study, said this research could be a very appropriate method for nickel extraction from an ore, especially when the world is thinking critically in the direction of carbon neutrality. The method produces high-purity ferronickel — an alloy with which stainless steel can be made — eliminating the need for extensive refining steps and making the overall process more sustainable on paper. 'However, the scalability of the mentioned study to an industrial production would involve certain challenges, including a high initial investment in infrastructure and renewable energy and limitations in ore applicability. Also, further in-depth study on thermodynamic kinetics may be required along with a demand for continuous free oxygen species supply at the arc-melt interface,' Mr. Kumar cautioned.
'Despite these hurdles, the study offers a promising, sustainable alternative to conventional nickel extraction methods.'
Hirra Azmat is a Kashmir-based journalist who writes on science, health, and environment.
Hashtags
Try Our AI Features
Explore what Daily8 AI can do for you:
Comments
No comments yet...
Related Articles
New Indian Express
20 hours ago
- New Indian Express
Stronger policies needed for Tamil Nadu to meet 2030 EV goals, says report
CHENNAI: A new report by the State Planning Commission and Guidance Tamil Nadu has stressed the need for strong policy support, failing which the state may not meet the nation's target to adopt Electric Vehicles (EVs) in over 20% commercial fleets by 2030. The study, titled Tamil Nadu's Automotive Future, outlines a roadmap for transforming the state into a hub for clean mobility innovation. It calls for the creation of a high-level Mobility Innovation and Growth Council with representation from government, industry and academia, to coordinate cross-sector efforts. A proposed 'Mobility Data Commons' would pool anonymised data from EVs, charging stations, and logistics platforms to inform real-time policy and urban planning. Tamil Nadu currently produces the majority of India's electric two-wheelers and accounts for nearly half of all auto exports. However, EV sales remain modest, accounting for only 6.6% of total vehicle sales as of August 2024.
Time of India
21 hours ago
- Time of India
Flat wiring: Powering the future of smarter, lighter vehicles
As vehicles grow increasingly intelligent and software-defined, their underlying architecture is undergoing a radical transformation. A key enabler in this shift is the growing adoption of flat wires and cables—designed to meet the demands of next-generation vehicle platforms that prioritise weight reduction, modularity, and software integration. Unlike traditional round wires or cables, flat wiring systems offer multiple performance benefits. These include enhanced space efficiency, reduced weight, better thermal management, and greater flexibility in routing, attributes especially valuable in modular and zonal vehicle architectures. 'In modern vehicles, flat wires are used in a number of areas such as battery packs and high voltage systems which enable high current transmission with better thermal dissipation. They are also used in e-motors and inverters due to better power density and higher cooling efficiency,' explains Jeffry Jacob , Partner and National Sector Leader for Automotive, KPMG in India. 'They (Flat wires) are better suited for zonal architectures due to lower wiring complexity. Some of the performance and design benefits are in the areas of space efficiency, better thermal management, weight reduction due to lesser copper and insulation, improved flexibility and better electrical efficiency.' Jacob further highlights their significance in electric vehicles (EVs), where every gram matters. 'Flat wires are also more modular and support a zonal architecture which is becoming common in next generation vehicles and reduces wiring complexity.' These wiring systems can be easily integrated into flexible printed circuits, he says, 'It also fits easily in confined spaces and makes harnesses plug and play, enabling modular repair and upgrades.' 'Both round and flat wires/cables have their own advantages and disadvantages. While the flat wires dominate in data, signalling and confined space applications, the round wires remain preferred in high current, harsh environment and negative zones,' shares S Siva Kumar, Sr. Vice President, R&D, Toyoda Gosei Minda . He adds that both kind of wires complement each other and are used based on application. Another senior official from a leading automotive component maker into wiring systems says, 'We're exploring aluminium as a substitute for copper in wiring systems to reduce costs and improve sustainability. Flat wires are gaining traction across multiple vehicle applications for their clear advantages.' He further notes that cross-industry innovation is underway. 'We are also studying how other industries use flat wiring/cabling, looking at examples we can adapt for the evolving automotive space.' While flat wires may involve a higher initial cost, the long-term benefits are compelling. They support sustainability goals through reduced material usage, lighter vehicle designs, and compatibility with automated harness production, leading to cost savings at scale. 'They are more amenable to automated assemblies which reduce labour costs, use less copper, and weighs less, which is very relevant for EVs and modular platforms,' highlights Jacob. Despite the advantages, flat wiring systems are not without challenges. Higher upfront investment is required for specialised materials, tooling, and manufacturing processes. 'They also require customised connectors and can be more difficult to access and repair compared to conventional harnesses,' points Jacob. As OEMs and component makers continue transitioning towards software-centric and electrified vehicle platforms, flat wiring is poised to become a foundational element of the future vehicle ecosystem, enabling smarter, lighter, and more efficient mobility solutions.
The Hindu
a day ago
- The Hindu
How extracting and producing nickel can be made more sustainable
Manzoor, U., Mujica Roncery, L., Raabe, D. et al, 'Sustainable nickel enabled by hydrogen-based reduction', Nature 641, 365–373 (2025). Nickel powers everything, from gadgets to green technologies. But getting it currently involves a far from green, in fact, a dirty process. However, a new study has revealed what its authors have said is a game-changing and sustainable method to extract nickel from low-grade ores using hydrogen plasma instead of carbon. It's a one-step process free of carbon dioxide that reportedly saves both energy and time. Nickel is an important metal used in several clean energy technologies, especially Electric Vehicles (EVs), and the demand for it is expected to surpass six million tonnes a year by 2040. While EVs are seen as a cleaner alternative to traditional fossil fuel-powered vehicles, there are hidden environmental costs associated with their production, especially in the manufacturing of lithium-ion batteries. A major component in these batteries is nickel and its extraction is highly carbon-intensive. Producing just one tonne of nickel can result in more than 20 tonnes of carbon dioxide emissions. So while EVs reduce emissions during operation, the process of sourcing materials like nickel simply shifts the pollution burden from the transportation sector to the mining and processing sector, among others. The methodology The study, published in Nature on April 30, was conducted by researchers at the Max Planck Institute for Sustainable Materials in Düsseldorf, Germany. In the study, the researchers bypassed the traditional multistep process to extract nickel — which includes calcination, smelting, reduction, and refining — and developed a single metallurgical step conducted in one furnace. 'The proposed method has the potential to be up to about 18% more energy efficient while cutting direct carbon dioxide emissions by up to 84% compared with the current practice,' the paper wrote. Ubaid Manzoor, a researcher at the Max Planck Institute and lead author of the study, said, 'Traditional nickel extraction is multi-step, energy-intensive and relies on carbon. Nickel oxide is heated with carbon, which removes the oxygen, producing pure nickel, along with carbon dioxide emissions.' The researchers have proposed replacing carbon with hydrogen as the reducing agent and using electricity as the energy source, specifically through an electric arc furnace. 'In our method, we use hydrogen plasma. Hydrogen gas, when subjected to high-energy electrons in an electric arc, splits into high-energy ions, entering a plasma state — the extremely hot and reactive fourth state of matter. It is distinct from solids, liquids, and gases. This hydrogen plasma rapidly reduces the metal oxides. From a thermodynamic perspective, the process is not only cleaner but significantly faster,' Mr. Manzoor said. He added that the method is kinetically superior — meaning the chemical reaction is more energetically favoured — thanks to the highly reactive and unstable nature of plasma. 'The end product of hydrogen reacting with oxygen is water, not carbon dioxide. Therefore, the entire process is carbon-free, using only electricity, hydrogen, and yielding water as a byproduct,' he added. Enabling sustainable production The study focused on laterite ores, a type of soil-rich rocks that contain metals like nickel. They form in hot, tropical regions when rain and heat break down rocks over time, leaving behind metal-rich layers. They are abundant but tough to process. 'While sulphide ores are found deeper underground and are easier to process, they're rapidly depleting. The new method used in the study works efficiently on laterites, making it key to future nickel production,' Mr. Manzoor said. India has substantial nickel laterite reserves, particularly in Odisha's Sukinda region. 'These deposits, containing 0.4-0.9% nickel as nickeliferous limonite in chromite mine overburden, are often overlooked because traditional methods require higher-grade ores. But [the team's method] excels at extracting value from these lower-grade resources,' Dierk Raabe, professor and director of the Max Planck Institute and co-author of the study, said. He added that the technology could play a major role as the demand for sustainably produced materials continues to grow. 'Without such innovations, the sustainability revolution — whether in electrification, renewables, or green infrastructure — risks merely shifting the carbon dioxide and energy burdens from one sector to another. In other words, we might build a 'greener' world through EVs, solar panels, and high-performance magnets while still relying on carbon-intensive methods to mine and refine the critical metals … that make all of it possible,' he said. The inescapable demand for nickel in multiple industries and its traditionally carbon-intensive production pose 'a particular challenge for countries like India, where rapid industrial growth is essential for economic development. India must simultaneously meet ambitious climate goals and leverage market opportunities in the green economy,' Mr. Raabe added. He continued that the technology aligns well with India's dual goals — to accelerate industrialisation and infrastructure development while staying committed to the goal of achieving net-zero emissions by 2070. It also reduces the need to import high-grade ores and maximises the potential of domestic, underutilised mineral assets, he added. Some challenges Pratik Kumar, assistant professor in the Department of Civil Engineering at IIT-Jammu and who wasn't associated with the new study, said this research could be a very appropriate method for nickel extraction from an ore, especially when the world is thinking critically in the direction of carbon neutrality. The method produces high-purity ferronickel — an alloy with which stainless steel can be made — eliminating the need for extensive refining steps and making the overall process more sustainable on paper. 'However, the scalability of the mentioned study to an industrial production would involve certain challenges, including a high initial investment in infrastructure and renewable energy and limitations in ore applicability. Also, further in-depth study on thermodynamic kinetics may be required along with a demand for continuous free oxygen species supply at the arc-melt interface,' Mr. Kumar cautioned. 'Despite these hurdles, the study offers a promising, sustainable alternative to conventional nickel extraction methods.' Hirra Azmat is a Kashmir-based journalist who writes on science, health, and environment.
