Grant: Alliance Grants

Canada ranks among the top five nickel-producing countries in the world due to the significant manufacture of nickel pellets, powders, and nanoparticles that are critical components in semiconductors, batteries, and catalysis. Ultra-pure nickel is commercially produced through the carbonyl or Mond process at a capacity of tons per hour, using nickel tetracarbonyl, Ni(CO)4 as the precursor. Since this process is thermal by nature, the toxicity and high flammability of Ni(CO)4 pose a significant risk for workers and the environment in case of accidental leakages or explosions. These complications make the research and development of nickel products produced by the Mond process prohibitively expensive. Researchers from Carleton University, Stanford University, and Vale Ltd. in Canada propose a comprehensive study on the high-temperature pyrolysis and oxidation of Ni(CO)4 and the development of the corresponding chemical kinetic model via high-level quantum chemistry to guide the assessment of appropriate risk assessment strategies and the establishment of methodologies aimed at overcoming the reliance on inefficient trial and error approaches in the exploration of new nickel materials. Classical molecular dynamics and simplified population balance modeling, areas of expertise of the principal investigator, will provide a broad theoretical picture of the Mond process. The research involves the design and assembly of a pilot-scale burner setup for the pyrolysis and oxidation of Ni(CO)4 under varying reaction conditions (e.g., precursor concentration, equivalence ratio, relative humidity). Vale Ltd. will build the experimental layout designed by Carleton teams under the guidance of the academic partners to meet the scientific standards and provide high-quality data on laminar flame speeds, flame temperatures, and emission spectroscopy of relevant intermediates to assist the construction of the chemical kinetic model. The project outcomes will provide a solid basis for future research, tools to systematically address the risks associated with handling the highly toxic Ni(CO)4, and foundations for the rational design of nickel materials.