Effective and economical treatment of low-grade nickel laterite by a duplex process of direct reduction-magnetic separation &amp; rotary kiln-electric furnace and its industrial application

Tian, Hongyu; Guo, Zhengqi; Zhan, Ruoning; Pan, Jian; Zhu, Deqing; Chao, Yang; Pan, Liaoting

doi:10.1016/j.powtec.2021.08.043

Cited by 23 publications

(3 citation statements)

References 28 publications

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“…The emphasis on utilizing nickel resources has transitioned toward laterite nickel ore. The advancement of ferronickel production using laterite has enabled the employment of Class II nickel for the manufacture of stainless steel, thereby substituting the costly Class I nickel (purity of >99% nickel). , Amidst the swift growth of the new energy sector and the limited capacity of Class I nickel, several nickel producers have declared their intention to transform nickel pig iron into nickel matte to be used as a raw material for battery production. , The conversion mentioned indeed helps address the issue of nickel shortages for batteries. However, the traditional ferronickel production method, the rotary kiln-electric furnace (RKEF) process, is known for its high-energy consumption and emission-intensive nature. − The reductive roasting-magnetic separation process has the potential to address these two issues effectively. , Furthermore, the magnetic concentrate obtained from this process shows excellent acid-leaching properties under atmospheric pressure …”

Section: Introductionmentioning

confidence: 99%

“…The advancement of ferronickel production using laterite has enabled the employment of Class II nickel for the manufacture of stainless steel, thereby substituting the costly Class I nickel (purity of >99% nickel). 4,5 Amidst the swift growth of the new energy sector and the limited capacity of Class I nickel, several nickel producers have declared their intention to transform nickel pig iron into nickel matte to be used as a raw material for battery production. 6,7 The conversion mentioned indeed helps address the issue of nickel shortages for batteries.…”

Section: ■ Introductionmentioning

confidence: 99%

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Enhanced Selective Reduction of Laterite for the Highly Efficient Enrichment of Ni and Co by NaFeS₂ and Its Recycling

Chen,

Xiao,

Rao

et al. 2024

ACS Sustainable Chem. Eng.

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The substantial demand for nickel and cobalt in the power battery industry presents an opportunity to convert powdery Ni−Co−Fe alloys, derived from laterite ores via solid-state reduction followed by magnetic separation, into battery-grade nickel and cobalt feedstock. To enhance the carbothermic solid-state reduction of laterite ores for the coenrichment of Ni and Co, NaFeS 2 was synthesized and applied as the additive to achieve the selective reduction of Ni and Co oxides over Fe oxides and to reject the majority of iron oxides and gangues into the tailings via magnetic separation. A powdery Ni−Co−Fe alloy with Ni and Co grades of 13.74 and 1.19%, respectively, and the corresponding recoveries of 93.41 and 81.93% was obtained. The addition of NaFeS 2 accelerated the growth of alloy particles by promoting the formation of the micro-zone liquid phase. Potential pollution problems caused by Na and S elements in tailings can be addressed through hydrothermal treatment of tailings, and also allows for the recycling of NaFeS 2 .

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Section: Introductionmentioning

confidence: 99%

Section: ■ Introductionmentioning

confidence: 99%

Enhanced Selective Reduction of Laterite for the Highly Efficient Enrichment of Ni and Co by NaFeS₂ and Its Recycling

Chen,

Xiao,

Rao

et al. 2024

ACS Sustainable Chem. Eng.

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“…The nickel used in the stainless steel industry accounts for approximately 66.2% of the total consumption of nickel worldwide, resulting in dramatically increased demand for nickel in recent years [4]. In nickel production, most metal nickel is produced from nickel sulfide ores, and laterite nickel ore only accounts for about 40% due to its complex mineralogy, low nickel and iron grades, and the high treatment cost [5]. However, with the diminution of high-grade nickel sulfide ores, recovering nickel from laterite nickel ore as an alternative of nickel sulfide ores is drawing increasing attention since laterite nickel ore constitutes 72.2% of the world's land-based nickel reserves [6][7][8].…”

Section: Introductionmentioning

confidence: 99%

High-Grade Ferronickel Concentrates Prepared from Laterite Nickel Ore by a Carbothermal Reduction and Magnetic Separation Method

Zhang,

Cao,

Xue

et al. 2023

Materials

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Nickel is widely used in industrial processes and plays a crucial role in many applications. However, most of the nickel resource mainly exists as nickel oxide in laterite nickel ore with complex composition, resulting in difficulty in upgrading the nickel content using physical separation methods. In this study, high-grade ferronickel concentrates were obtained through a carbothermal reduction and magnetic separation using laterite nickel ore and anthracite as raw materials. The effects of different types of additives (CaF2, Na2SO4, and H3BO3), carbon ratio (the molar ratio of oxygen atoms in the laterite nickel ore to carbon atoms in anthracite), and grinding time on the recoveries and grades of ferronickel concentrates were experimentally investigated, along with the microstructure and chemical composition of the products. CaF2 was proved to be the primary active additive in the aggregation and growth of the ferronickel particles and the improvement of the grade of the product. Under the optimal conditions of CaF2 addition of 9.85 wt%, carbon ratio of 1.4, and grinding time of 240 s, high-grade magnetically separable ferronickel concentrate with nickel grade 8.93 wt% and iron grade 63.96 wt% was successfully prepared. This work presents a practical method for the highly efficient recovery and utilization of iron and nickel from low-grade laterite nickel ore, contributing to the development of strategies for the sustainable extraction and utilization of nickel resources.

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Artificial Slags with Modulated Properties for Controlled Nickel Dissolution in Smelting Process

Urtnasan,

Kumar,

Wang

2024

Trans Indian Inst Met

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In pyrometallurgy process involving drying, calcination and reductive smelting steps, Saprolite ore is subjected in an electric arc furnace to produce Fe–Ni alloy and Ni matte. To optimize the nickel smelting step, the slag consisted of MgO–SiO2–FeO and having a lower viscosity and high fluidity is required. In this study, a number of new slag samples with varied degree of compositions are manufactured and used to examine the effect of their viscosity on nickel dissolution. Further correlation between the slag basicity and FeO addition on the smelting was also tested and simulated using Fe–Ni alloy from saprolite ore. As per the observations, the nickel dissolution increases with the increased content of FeO at a certain degree of activity which in turn can cause oxidation of nickel during the process. The slags with the ratio of MgO/SiO2 = 0.4–0.6, 30% fraction of FeO, and a viscosity of 1.8–1.06 poise in the olivine zone are found effective for the lowest dissolution rate of nickel with 0.021, 0.022, and 0.018 wt.%. The lowest dissolution rate is recorded for the slag with MgO/SiO2 ratio about 0.6. These slags with controlled amount of constituents could be used to recover precious metal from nickel smelter at a lower dissolution rate and thereby allowing to reduce the waste of the metal during smelting process.

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Effective and economical treatment of low-grade nickel laterite by a duplex process of direct reduction-magnetic separation & rotary kiln-electric furnace and its industrial application

Cited by 23 publications

References 28 publications

Enhanced Selective Reduction of Laterite for the Highly Efficient Enrichment of Ni and Co by NaFeS₂ and Its Recycling

Enhanced Selective Reduction of Laterite for the Highly Efficient Enrichment of Ni and Co by NaFeS₂ and Its Recycling

High-Grade Ferronickel Concentrates Prepared from Laterite Nickel Ore by a Carbothermal Reduction and Magnetic Separation Method

Artificial Slags with Modulated Properties for Controlled Nickel Dissolution in Smelting Process

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Effective and economical treatment of low-grade nickel laterite by a duplex process of direct reduction-magnetic separation & rotary kiln-electric furnace and its industrial application

Cited by 23 publications

References 28 publications

Enhanced Selective Reduction of Laterite for the Highly Efficient Enrichment of Ni and Co by NaFeS2 and Its Recycling

Enhanced Selective Reduction of Laterite for the Highly Efficient Enrichment of Ni and Co by NaFeS2 and Its Recycling

High-Grade Ferronickel Concentrates Prepared from Laterite Nickel Ore by a Carbothermal Reduction and Magnetic Separation Method

Artificial Slags with Modulated Properties for Controlled Nickel Dissolution in Smelting Process

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Product

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Enhanced Selective Reduction of Laterite for the Highly Efficient Enrichment of Ni and Co by NaFeS₂ and Its Recycling

Enhanced Selective Reduction of Laterite for the Highly Efficient Enrichment of Ni and Co by NaFeS₂ and Its Recycling