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Recovery of nickel and iron from low–grade laterite ore and red mud using co–reduction roasting: Industrial-scale test

Guo Xiaoshuang, Xu Chengyan, Wang Yingshuo, Li Xiaohui, Sun Tichang

Physicochemical Problems of Mineral Processing

2021

Vol. 57, iss. 3

61--72

In this study, the effects of red mud (RM) dosage during the co-reduction roasting of lowgrade laterite ore and RM were investigated. The expanded test was conducted under the following optimized conditions: RM-1 dosage of 15 wt%, anthracite dosage of 13 wt%, a roasting temperature of 1300oC, and roasting time of 3 h. Ferronickel powder was obtained with a nickel grade of 1.95 wt%, iron grade of 83.25 wt%, and nickel and total iron recoveries of 94.71 wt% and 95.98 wt%, respectively. The addition of RM improved the recovery of nickel and total iron in ferronickel powder. The reason was because of the increased intensity of the diffraction peaks of kamacite and iron, and the ferronickel particles grown due to the liquid phase were easier to achieve at a lower melting point. The industrialscale test results showed that ferronickel powder was obtained with average nickel and total iron grades of 1.76 wt% and 86.46 wt%, respectively, which indicated the successful industrial-scale test of co–reduction roasting. Thermodynamic analysis theoretically illustrated the feasibility of the co–reduction of low-grade laterite ore and RM. Increased roasting temperature promoted the reduction of iron oxide and nickel oxide.

Effects and mechanism of Bayer red mud on co-reduction with a saprolitic laterite ore to prepare ferronickel

Wang Xiaoping, Sun Tichang, Wu Shichao, Hu Tianyang, Rong Lingkun

Physicochemical Problems of Mineral Processing

2020

Vol. 56, iss. 4

641--652

Co-reduction of a saprolitic laterite and waste Bayer red mud was investigated to prepare ferronickel powder. The synchronous reduction and comprehensive recovery of nickel and iron in the low-grade laterite ores and iron in the red mud were realized. At the red mud dosage of 50 wt%, ferronickel powder with nickel and iron grades of 5.58 wt% and 89.91 wt% was obtained. The corresponding nickel and total iron recoveries were 93.11 wt% and 90.23 wt%, respectively. The red mud enhanced the nickel recovery of the saprolitic laterite ore evidently, attributing to the formation of low-melting anorthite, omphacite, and diopside during co-reduction. This led that NiO in the saprolitic ore was released. Meanwhile, obvious melting phenomenon of the roasting system was appeared, enhancing the growth of the ferronickel particles.