ADVANCES AND INNOVATIONS IN FERRONICKEL-MAKING

1 An Overview of Nickel Utilization from Laterite Ore 1.1 Applications of Nickel 1.2 Demand of Nickel 1.3 Resources of Nickel 1.4 Metallurgical Processes of Laterite Ore 1.4.1 Hydrometallurgical Processes 1.4.2 Pyrometallurgical Processes 1.5 Challenges and Development of Ferronickel-Making References 2 Fundamentals of Selective Solid-State Reduction and Novel Process for Preparing Ferronickel from Laterite Ore 2.1 Thermodynamics of Reduction/Sulfidation of Nickel and Iron Oxides 2.1.1 Thermodynamics of Reduction 2.1.2 Thermodynamics of Sulfidation 2.2 Behaviors of Selective Reduction/Sulfidation of Laterite Ore 2.2.1 Influencing Factors of Reduction/Sulfidation 2.2.2 Kinetics of Reduction/Sulfidation 2.3 Formation and Growth of Ferronickel Particles During Solid-State Reduction 2.3.1 Phase Transformation 2.3.2 Softening-Melting Property 2.3.3 Microstructure 2.3.4 Growth Mode of Ferronickel Particles 2.4 New Process of Preparing Ferronickel Through Selective Solid-State Reduction-Magnetic Separation and Its Application 2.4.1 Main Technological Parameters 2.4.2 Pilot-Scale Test of Direct Reduction Within \"Firing Model\" of Rotary Kiln 2.4.3 Industrial Test of Direct Reduction-Magnetic Separation in Coal-Based Rotary Kiln 2.4.4 Comparison Between the New Process and Existing Processes References 3 Technology of Slag Formation Control in Electric Furnace Smelting of Laterite Ore 3.1 Phase Diagrams of Slag Systems 3.1.1 MgO¨CSiO2¨CAl2O3 Slag System 3.1.2 MgO-SiO2-Al2O3-FeO Slag System 3.1.3 CaO¨CMgO¨CSiO2¨CAl2O3¨CFeO Slag System 3.2 Liquid Phase Formation During Smelting 3.2.1 Effect of CaO Content 3.2.2 Effect of FeO Content 3.2.3 Effect of MgO Content 3.2.4 Effect of Al2O3 Content 3.3 Viscosity Behavior of Slag 3.3.1 Effect of CaO Content 3.3.2 Effect of FeO Content 3.3.3 Effect of MgO Content 3.3.4 Effect of Al2O3 Content 3.3.5 Verification Tests 3.4 Technics for Controlling Slag Formation 3.5 Applications of Controlling Slag Formation 3.5.1 Effect of Coke addition 3.5.2 Effect of Quaternary Basicity of Slag 3.5.3 Effect of Smelting Temperature 3.5.4 Effect of Smelting Time 3.6 Pilot-Scale Tests 3.6.1 Raw Materials 3.6.2 Experimental Procedure 3.6.3 Results and Discussion 3.7 Industrial Applications 3.7.1 Industry Practice in Plant 3.7.2 Industry Practice in Plant 3.7.3 Assessment of Energy Conservation and Emission Reduction References 4 Softening-Melting Properties of Laterite Ore and Regulation Technology Applied in Krupp-Renn Process and Sintering Process 4.1 Phase Transformation of Laterite Ore During Roasting 4.1.1 Experimental 4.1.2 Effect of CaO Content 4.1.3 Effect of Roasting Temperature 4.1.4 Effect of CO Partial Pressure 4.2 Characteristic Fusion Temperatures of Laterite Ore 4.2.1 Effect of CaO Content 4.2.2 Effect of CO Partial Pressure in Reducing Atmosphere 4.2.3 Effect of FeO Content 4.3 Regulation Technology of Softening¨CMelting Performance of Laterite Ore 4.4 Regulation Technology Applied in the Krupp-Renn Process 4.4.1 Growth Behaviors of Ferronickel Particles 4.4.2 Grinding¨CMagnetic Separation of Ferronickel from Reduced Laterite Ore 4.4.3 Comparison with the \"Oheyama Process\" 4.5 Regulation of Sintering Process 4.5.1 Sintering of Saprolitic Laterite Ore 4.5.2 Sintering of Limonitic Laterite Ore References 5 Valorization of Ferronickel Slag for Preparation of Value-Added Materials 5.1 Properties of Ferronickel Slag 5.2 Current Status of Utilization of Ferronickel Slag 5.2.1 Production of Building Materials 5.2.2 Preparation of Functional Materials 5.2.3 Recovery of Valuable Metals ¡­¡­