Effects of direct reduction process on the microstructure and reduction
A coal-based direct reduction process was used to recover the ferronickel from low-grade nickel laterite ore. The effects of basicity on the compressive strength, metallization rate ...
A Review of Direct Reduction–Magnetic Separation Process …
This paper aims to fill these gaps by presenting the current state of thermal treatment and magnetic separation processes for ferronickel production through the direct …
A Review of Direct Reduction–Magnetic Separation …
Ferronickel, produced from the thermal upgrading of nickeliferous ores, is one of the feed materials for stainless steel production. However, traditional high-temperature smelting …
Ferronickel Preparation from Nickeliferous Laterite by …
In the recent years, ferronickel has been used as a substitute for electrolytic nickel for alleviating the cost of stainless steel production. Rotary kiln-electric furnace (RKEF) smelting is currently the world-wide mainstreaming process for ferronickel production from nickeliferous laterite ore, in spite of the high power consumption.
Ferronickel smelting plant Electric furnace off-gas …
1 Ferronickel smelting plant and process Kawasaki's ferronickel smelting plant follows the process shown in Fig. 1. Ferronickel ore with 1.8-2.2% nickel content is first dried in a rotary dryer, then reduced in a rotary kiln. Next, the ore is smelted in an electric furnace and separated into slag and metal (ferronickel) with
Direct Reduction Process
The MIDREX ® direct reduction process uses a natural-gas-based shaft furnace process that converts iron oxides (pellets or lump ore) into DRI. The MIDREX direct reduction technology has evolved during the past four decades from plant capacities of just 150,000 t/year to capacities now approaching 2 million t/year [34].
Application of coal-based direct reduction-magnetic …
Coal-based direct reduction (CBDR) in iron ore smelting, emerging as a prominent method in the mid-20th century, represents a significant evolution in response to energy crises and environmental concerns, entails the removal of oxygen from solid iron ore to produce solid sponge iron that can be used in electric arc furnace (EAF) steel production (Wang et al., 2021, …
Material and energy flows in rotary kiln-electric furnace smelting …
Pilot plant production of ferronickel from nickel oxide ores and dusts in a DC arc furnace. Miner. Eng. (2002) ... A coal-based direct reduction process was used to recover the ferronickel from low-grade nickel laterite ore. The effects of basicity on the compressive strength, metallization rate, microstructure, and reduction characteristics of ...
Effective and economical treatment of low-grade nickel …
At present, based on the difference of treated methods and final products, the main commercial processing routes for the treatment of nickel laterite can be classified into two types, namely pyrometallurgical processes for ferronickel (e.g. rotary kiln-electric furnace process, direct reduction-magnetic separation process, and sintering-blast ...
Method for producing ferronickel by adopting rotary kiln direct …
The invention provides a method for producing ferronickel by adopting a rotary kiln direct reduction-RKEF (Rotary Kiln-Electric Furnace) combination method. The method comprises the following steps: drying a laterite nickel ore for later use; crushing and screening an appropriate amount of the dried laterite nickel ore, and then mixing the screened laterite nickel ore with a …
Direct reduction of low grade nickel laterite ore to produce
In this study, low grade nickel laterite ore was processed by means of isothermal-temperature gradient method to produce ferronickel nugget. The ore and coal as reductant …
High-Grade Ferronickel Concentrates Prepared from Laterite …
Fine grinding of the as-prepared ferronickel concentrates is beneficial to improve the iron and nickel grades by separating the ferronickel particles from the concentrates. After carbothermal reduction, the as-prepared ferronickel concentrates were fine ground, and their particle size distribution is shown in Table 4 and Figure 5 a.
Advances and Innovations in Ferronickel-Making
Based on a detailed overview of nickel utilization from laterite ores, it provides the advances of four main methods for laterite ore processing, including the solid-sate reduction-magnetic separation process, the rotary kiln …
Sustainable steel through hydrogen plasma reduction of …
The reduction rate of hydrogen plasma-based reduction, using only a small H 2 partial pressure of 10%, is comparable with those ones observed in solid-state direct reduction of hematite conducted at temperatures currently employed in shaft furnaces (850–1000 °C). The rate-limiting barriers (i.e. diffusion of oxygen species in the solid state ...
Ferronickel
These ores are smelted to produce either ferronickel or matte. The rotary reduction kilns are normally lined with CO-resistant castables that have sections of similarly CO-resistant brick. The electric ferronickel furnaces are designed with magnesia-and-tar-impregnated magnesia-based working linings. ... A direct-bonded, 65% magnesia, 18% ...
Production of ferronickel from limonitic laterite ore using …
The ferronickel for steel-making has different grades based on the compositions of Ni, namely low-grade ferronickel (5% to 20% Ni) and high-grade ferronickel (35% to 40% Ni) (Solar et al., 2008). As the treatment of the ore is diversified widely depending on the nickel content and other components, it is obvious that both lower and higher ...
A Review of Direct Reduction–Magnetic Separation Process …
In this work, high-grade ferronickel concentrate was prepared by a reduction roasting-magnetic separation process, and low-grade ferronickel concentrate and CaF2 were used as composite additives ...
Pilot plant production of ferronickel from nickel oxide …
In ferronickel production, the nickel oxide and part of the iron oxide are reduced to metal in an electric furnace to form immiscible layers of slag and metal. ... Dehydration as a minimum, and some pre-reduction of the ore in a rotary kiln is used to optimize the utilization of electric energy for smelting operations in the conventional ...
Pilot plant production of ferronickel from nickel oxide ores …
Semantic Scholar extracted view of "Pilot plant production of ferronickel from nickel oxide ores and dusts in a DC arc furnace" by I.J Kotzé ... A pyrometallurgical process was developed for the recycling of Ni bearing dusts and laterite ore fines by direct reduction smelting in DC (direct current) arc furnace. In the course of the performed ...
Pilot scale test of producing nickel concentrate from low …
LI Guang-hui, RAO Ming-jun, JIANG Tao, HUANG Qing-qing, SHI Tang-min, ZHANG Yuan-bo. Innovative process for preparing ferronickel materials from laterite ore by reduction roasting-magnetic separation [J]. Trans Nonferrous Met Soc China, 2011, 21(12): 3137–3142. (in Chinese) Google Scholar
Pilot-scale plant study on solid-state metalized reduction…
An innovative technology named solid-state metalized reduction–magnetic separation (SSMRMS) was developed to produce ferronickel concentrates from magnesium-rich nickel oxide ores. A pilot-scale plant with a daily processing capacity of 500 kg of dry ores was assembled and tested. SSMRMS involves four steps: feed preparation, solid-state ...
Green Hydrogen-Based Direct Reduction for Low …
reduction of up to 95% if renewable electricity is used.[8] These processes are currently under development. The same also applies for processes replacing carbon-containing reducing agents by hydrogen either in solid state (direct reduction [DR]) or in …
CN108251659B
The invention discloses a method for preparing ferronickel by a reinforced laterite-nickel ore direct reduction process, which is to prepare a ferronickel product by adding a certain mass proportion of alkaline flux into laterite-nickel ore and adopting a rotary kiln direct reduction process. In the process of reduction roasting, the contents of calcium oxide and ferrous oxide in the laterite ...
The Nickel Production Methods from Laterites and …
Primary world nickel production in 2020 was 2430.7 kt Ni; 69% (1677.7 kt) of them came from oxidized nickel ores (laterites) and 31% from sulfides. Production-wise, 87.7% of the 1677.7 kt came from pyrometallurgical and 12.3% from …
Ferronickel
An evaluation of operations with high and low amounts of iron reduction is shown Table 6.2.Generally, high reduction of iron (lower content of nickel in ferronickel) is favored when (i) high recovery of nickel is critical, (ii) a reasonable price is realized for the Fe in the ferronickel; and, (iii) the costs of transportation of the ferronickel to market are low.
Technology of Ferronickel
The chemical composition of nickel ores varies widely from plant to plant—(% wt.): 1 to 3 Ni, 0.03 to 0.1 Co, 10 to 32 Fe, ... it is natural that both lower and higher reduction degrees are used. ... Ferronickel is usually cast on conveyor machines in ingots of 25 to 35 kg weight. The specific energy consumption for processing 1 ton of dry ...
Direct reduction of low grade nickel laterite ore to produce
In this study, low grade nickel laterite ore was processed by means of isothermal-temperature gradient method to produce ferronickel nugget. The ore and coal as reductant were ground to obtain the ...
Ferronickel Production from Nickel Laterite via Sulfide …
The iron to nickel ratio in saprolite is similar to that employed in ferronickel, allowing it to undergo direct pyrometallurgical co-reduction of iron and nickel species . The nickel content may be further upgraded by sulfidation of the ferronickel to matte for subsequent iron/nickel separation via matte smelting.
Large- and Particle-Scale energy assessment of reduction …
Ferronickel (FeNi), with CAS number 11110–39-7, originates from nickel sulfide and oxide ores and contains around 55–75 % wt Fe and 25–45 % wt Ni [1].The depletion of nickel sulfide ores and their challenging extraction have prompted the exploitation of nickel oxide ores [2].Limonitic and saprolitic are typical nickel oxide ores with nickel contents of around 0.5–1.8% …
Direct reduction plants
Ezz Steel has invested heavily in direct reduction plants (DRPs) to provide the highest quality direct reduced iron (DRI) feedstock for its steelmaking processes. The most recent investment of $550m in a new DRI plant at the Suez plant brings our total DRI output capacity to 5 million tons per year. That made Ezz Steel the largest producer of ...