Nickel Laterite Smelting Processes and Some Examples of …
2. Alternative Nickel Laterite Smelting Processes to the Rotary Kiln-Electric Furnace (RKEF) Process 2.1. The Vaniukov Process The Vaniukov process is a well-established technology for pyrometallurgical treatments, especially for the smelting of copper ores [11,12]. Its use in laterite smelting was studied in the last decade.
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The Effect of Sulfur in Rotary Kiln Fuels on Nickel Laterite …
Rotary Kiln - Electric Furnace (RKEF) process is a pyrometallurgical technique to extract nickel from laterite ores. It is essentially a two-step process where the ore is first calcined in a rotary kiln and then smelted in an electric furnace. The product of …
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Preparation of ferronickel from nickel laterite via coal-based
The sticking phenomenon between molten slag and refractory is one of the crucial problems when preparing ferronickel from laterite ore using rotary hearth furnace or rotary kiln processes. This study aims to ameliorate sticking problems by using silicon dioxide (SiO2) to adjust the melting degree of the briquette during reduction roasting. …
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The effect of sulfur in rotary kiln fuels on nickel laterite
Rotary Kiln - Electric Furnace (RKEF) process is the most commonly used pyrometallurgical technique for processing nickel laterite ores and is mainly suited for …
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Process simulation and exergy analysis of two nickel laterite
Two-thirds of the global nickel output can be attributed to the rotary kiln-electric furnace process. Due to the high contents of MgO and SiO 2 in laterite, a high temperature (∼1600 °C) and corresponding energy (approximately 14 GJ/t-ferronickel) are required during the electric furnace smelting.
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Separation and recovery of iron and nickel from low-grade laterite
The low-grade laterite ores used in this study was obtained from Fuzhou City, Fujian Province in China, and they are a typical saprophytic laterite ore. The main chemical composition of the laterite nickel ore is 1.71 wt.% TNi, 20.37 wt.% TFe, 25.56 wt.% SiO 2, 17.85 wt.% MgO and 2.50 wt.% Al 2 O 3.
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(PDF) Large- and Particle-Scale Energy Assessment of
The rotary kiln furnace shows energy and exergy efficiencies of 66.4% and 32.3%, respectively, leaving room for waste heat recovery. Particles with surface-to-center distances lower than 5.0 mm ...
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Selective Reduction of Laterite Nickel Ore
2.3 Direct reduction of laterite nickel ore in industrial scale Most laterite nickel ore processing is carried out using Elkem process. The Elkem process uses Rotary Kiln and Electric Furnace (RKEF) to reduce and smelt laterite nickel ore. Commercialization of Elkem process itself began with the development of a pilot plant in 19531954. At ...
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Open Access proceedings Journal of Physics: Conference …
cheap electricity sources. Unlike sulfide ores, nickel in laterite is finely dispersed in ore and cannot be increased by fine grinding or other physical methods [3]. There are three main processes of commercial processes: rotary kiln electric furnaces (RKEF) and rotary kiln magnetic separators, Caron process, and high pressure acid leaching (HPAL).
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Preparing Ferro-Nickel Alloy from Low-Grade Laterite …
In saprolitic laterite nickel ore, the contents of silicon, magnesium and nickel are high, while that of iron and cobalt are low, which is appropriately treated by pyrometallurgical processes, such as rotary …
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(PDF) Improving the rotary kiln-electric furnace process for
The primary pyrometallurgical route to produce ferronickel from laterite nickel ores is the Rotary Kiln-Electric Furnace (RKEF) process. In the RKEF process, …
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Metals | Free Full-Text | Nickel Laterite Smelting Processes and …
Industrially, the pyrometallurgical treatment of laterites is mostly accomplished with a well-established method, namely, the rotary kiln–electric arc …
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The effect of sulfur in rotary kiln fuels on nickel laterite
Rotary Kiln - Electric Furnace (RKEF) process is the most commonly used pyrometallurgical technique for processing nickel laterite ores and is mainly suited for saprolite deposits. Sulfur is one of the harmful elements in crude ferronickel obtained via the RKEF process. Typically, laterite ores contain insubstantial sulfur content; hence, it is …
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Exergy assessment of a rotary kiln-electric furnace smelting of
They concluded that the slag, flue gas of electric furnace, flue gas of rotary kiln and the sensible heat of laterite ores calcined are valuable for recovery. In fact, part of their suggestions have been applied in the present RKEF process. Norgate et al. [14] presented a life cycle assessment for the energy of nickel laterite processing.
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Enhancing Rotary Kiln-Electric Furnace Process of Saprolitic Laterite
How to reduce the energy consumption of the rotary kiln-electric furnace (RKEF) process has become an important issue for the stainless steel industry. The aim of this study is to reduce the energy consumption of ferronickel production from saprolite nickel laterite in the RKEF process. The effects of the slag binary basicity, FeO content, and …
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Preparation of Ferronickel from Nickel Laterite Ore via Semi …
With continuous consumption of high-grade sulfide resources, the use of nickel laterite has drawn increasingly attention [6,7,8]. Up to now, the pyrometallurgical method, namely the rotary kiln-electric furnace (RKEF) process, has been applied to produce ferronickel from nickel laterite ore [9, 10].
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Material and energy flows in rotary kiln-electric furnace smelting of
The primary pyrometallurgical route to produce ferronickel from laterite nickel ores is the Rotary Kiln-Electric Furnace (RKEF) process. In the RKEF process, minerals undergo calcination and partial reduction in a rotary kiln. Large amounts of mineral dust leave the kiln entrained in flue gases. Dust insufflation is a potential solution in ...
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Direct reduction method for smelting ferronickel in rotary kiln
The nickel iron smelting process of existing maturation be rotary kiln-mineral hot furnace technique wherein: first josephinite is transported in toothed roll crusher broken by apron feeder, josephinite after fragmentation enters and in dryer, reduces water content, by the ferronickel after drying with go back raw coal, Wingdale and drop in mixer and mix …
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Material and energy flows in rotary kiln-electric furnace smelting of
The rotary kiln-electric furnace process is the one of the most widely adopted technological process for ferronickel smelting production. A schematic of the RKEF process with rotary dryer, rotary kiln and electric furnace is shown in Fig. 1.As depicted, the RKFF process involves three main processes: the dehydration process in rotary dryer; …
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Evolution of ferronickel particles during the reduction of
and/or pyrometallurgy. In general, saprolitic laterite nickel ore is processed by pyrometallurgy and limonite is processed by hydrometallurgy. Through pyrometallurgy, there are three proven technologies for the processing of saprolitic laterite nickel ore, namely, RKEF (rotary kiln–electric furnace), blast furnace, and Krupp–Renn.
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ANNUAL REPORT AND APPENDIX 4E Highlights: US$ US
The Group's principal operations, located in Central Sulawesi, Indonesia, are the Hengjaya Nickel and Ranger Nickel rotary kiln electric furnace ('RKEF') projects located within the Indonesia Morowali Industrial Park ('IMIP'), the ... grade nickel laterite deposit in close proximity to the IMIP. Additionally, the Company has executed ...
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Exergy assessment of a rotary kiln-electric furnace smelting of
Among these methods, the rotary kiln-electric furnace (RKEF) process is widely used in China due to its advantages of good adaptability for various nickel laterite, less harmful elements, high production efficiency and mature process [10]. However, the RKEF process suffers from the high energy consumption and a large amount of by …
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The Best Mining Equipment for Philippines Nickel Ore You Must …
The development of nickel laterite mines needs to consider the differences in nickel ore types, cobalt content, as well as the local supply of fuel, water, electricity, and chemical reagents. From a global perspective, the Pre-reduction of Rotary Kiln &Electric Furnace Reduction is still in a dominant position in the development of laterite ...
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Ferronickel | SpringerLink
Smelting of Laterite Nickel Oxide Ore It mainly includes blast furnace method, rotary kiln direct reduction method, and rotary kiln-submerged arc furnace combined …
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Ferronickel Preparation from Nickeliferous Laterite by Rotary Kiln
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 …
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Materials Proceedings | Free Full-Text | The Nickel Production …
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 hydrometallurgical processes. For a long time, Fe-Ni had a 20–40% Ni analysis, but in 2006 a new Fe-Ni quality came into …
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Ferronickel Preparation from Nickeliferous Laterite by Rotary Kiln
Rotary kiln-electric furnace (RKEF) smelting is currently the world-wide mainstreaming process for ferronickel production from nickeliferous laterite ore, in spite …
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Effective and economical treatment of low-grade nickel laterite by …
The construction of DRMS process on such a scale needs two rotary kiln lines with each production scale of 50 t/d for the reduction of nickel laterite. The two rotary kiln lines share the same systems including burden system, briquette system, screening system, mill control system and mineral separation system, and the capital cost …
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Upgrade of nickel and iron from low-grade nickel laterite by …
2.1 Materials 2.1.1 Nickel laterite ore. The chemical composition of nickel laterite as received from Philippines employed in the study is shown in Table 1.It indicates that the nickel laterite contains 1.29 wt.% Ni, 16.31 wt.% Fe, 32.28 wt.% SiO 2 and 27.38 wt.% MgO with both high Fe/Ni of 12.64 and MgO/SiO 2 of 0.85, while the impurity …
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The Impacts of Temperature, Gas Composition and Reaction
Rotary kiln-electric furnace (RKEF) technology accounts for 95 pct of the lateritic nickel ore processing. Coal is commonly used as fuel and reducing agent in the rotary kiln to produce solid reduction product which is then melted in the electric furnace. The use of coal in the process leads to the emission of approximately 70 tons of CO2 for …
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