Outokumpu Harjavalta Metals Oy has been producing nickel since 1962, based on conventional flash smelting technology followed by electrowinning of nickel. In the 1980s, a research project was initiated to develop a converterless direct smelting process to produce matte for further refining in the then existing refinery. The process was tested …
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ing, direct flash smelting and converting (DON), Ausmelt nickel smelting and converting, and slag cleaning furnaces. Our unique technology solutions include laboratory testing, engineering and delivering ... The leaching process results in an aqueous nickel and/or cobalt sulfate solution. This solution is further treated through iron, manganese ...
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The Nickel Mining Process. ... necessitating the use of energy from other sources for smelting. Nickel matte remains after the mining and processing of either lateritic or sulfidic ore. Using the fluid bed roasting procedure, a 95 percent pure nickel can be achieved after additional refinement.
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The commercial operations for the Caron process are located at Nicaro, Punta-Gorda, and Yabulu/BHP-Billiton nickel. Caron process also handles higher levels of magnesia. Smelting is a preferred choice when it is intended to recover both Ni, and MgO values as ferronickel, and high MgO slag, respectively.
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Using nickel concentrate or nickel-copper bulk concentrate as raw materials produces intermediate-product high-grade nickel matte. Three process methods are mainly used: low-shaft electric furnace method, direct smelting, and direct Outotec nickel (DON) smelting. Low-Shaft Electric Furnace Method. This is a traditional technology. This …
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Experience of the direct Outokumpu nickel (DON) smelting process gained over the first ten years of operation is reviewed, including the significant environmental impacts. In 1995, production capacity at Harjavalta was increased from 17 000 to 52 000 t/year, by introducing DON technology, additional refinery capacity being based on …
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Flash Smelting and Flash Converting process. With flexibility, low energy consumption, high sulfur capture, and excellent economy of scale, Outotec Flash Smelting technology is the world's leading method for copper and nickel smelting. More than half of the world's primary copper and nickel is produced using
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The flash smelting process has grown to be a major technology in copper and nickel sulfide smelting along with various bath smelting techniques. The attractiveness of the flash smelting is due to, e.g., its high on-line availability, high copper yield, low need of external energy, high sulfur fixing and small carbon footprint.[ 1 ]
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1.4.2.1 Matte Smelting Process. The nickel matte smelting process has been applied since 1920s and it was the first pyrometallurgical process of laterite ore in industrial production [80, 81]. By adding sulfur, sulfide ore or gypsum into laterite ore, the low-grade nickel matte ...
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The smelting process depends on the different ways in which the free energies of reactions like (ref{2.4}) and (ref{2.4}) vary with the temperature. This temperature dependence is almost entirely dominated by the T Δ S ° term in the Gibbs function, and thus by the entropy change.
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nickel processing, preparation of the metal for use in various products. Although it is best known for its use in coinage, nickel (Ni) has become much more important for its many industrial applications, which owe …
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Concentration Smelting & Converting Refining •Rely on third party PGM refiners •Smelting associated with the huge nickel infrastructure • Recoveries associated with Nickel •Outsourced PGM refining to Heraeus •Excess base metal outsources to AAP and Empress as nickel sulphate •Furnace reliability challenging due to
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Industrially, the pyrometallurgical treatment of laterites is mostly accomplished with a well-established method, namely, the rotary …
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A computer model has been developed to simulate the nickel smelting process. The primary assumption of the model is that six phases in the nickel smelting furnace are in chemical equilibrium. The amounts of all components in matte, slag and gaseous phases under equilibrium are calculated by using the data of free energies of formation and …
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In this review, resources of nickel and status of different processes/technologies in vogue or being developed for extraction of nickel and associated metals from both primary and secondary ...
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The two main processing methods for laterite ores are smelting and High-Pressure Acid Leaching (HPAL). Smelting is used primarily on saprolite ores to obtain …
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Relevant work had found that the iron phase in nickel residues is mainly in the form of 2FeO·SiO 2, which is produced by SiO 2 addition as flux during slag formation in the nickel smelting process.[1,2,3] Due to the poor magnetic separation character and reducibility, it is difficult to extract iron from the residual slag and use it effectively.
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The unavoidable impacts of mining, smelting, and refining Class 1 nickel. Leaving aside the impending shortage of Class 1 nickel, mining inevitably has an impact on an asset's surroundings. ... The …
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• Raw Materials: Smelting begins with raw materials, typically metal ores, which contain the target metal in combination with various impurities. • Heat Source: High temperatures are applied to the raw materials, often using furnaces or specialized smelting equipment, to initiate the smelting process.
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The treatment of laterites has been a research hotspot in extractive metallurgy over the past decades. Industrially, the pyrometallurgical treatment of laterites is mostly accomplished with a well-established method, namely, the rotary kiln–electric arc furnace (RKEF) process, which includes three main operations—calcination, …
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Nickel smelting and converting Ausmelt TSL Furnaces have been designed, built and operated to handle nickel concentrates with nickel content as low as 5%. Nickel converting is also available to upgrade low grade mattes before refining. PGM recovery can be targeted specifically using the Ausmelt TSL Process. Similarly,
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QNI's nickel and cobalt refinery processes 3.6 million tpa of lateritic nickel ore, based on the Caron process, Anthony and Flett (1997). QNI Ltd.'s cobalt refinery presently produces about 1500 tpa of QN cobalt oxide hydroxide with low levels of impurities. Nickel powders and briquettes are produced at WMC's nickel refinery in …
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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 …
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During the smelting process, sulphur and other impurities are removed from the nickel concentrate. Sari Muinonen, Process Technology and Custom Feed Manager, has worked at the Sudbury smelter since 2010. We have a furnace that operates at about 1,380 degrees Celsius. The material gets dropped into the top, falls through …
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Reduction–sulfurization smelting is an effective method for treating solid hazardous waste and recovering valuable components from them. In this work, a waste hydrogenation catalyst (WHC), an automotive exhaust purifier waste catalyst (AEPWC), a vulcanizer, and laterite nickel ore were mixed, and the reduction smelting behavior of …
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Learn about the technology and process of extracting nickel from nickel-bearing minerals and secondary resources. Find out how nickel sulfide ore and laterite-nickel ore are …
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Older nickel-smelting processes, such as blast or reverberatory furnaces, no longer are acceptable because of low-energy efficiencies and environmental concerns. ... The Mitsubishi continuous copper smelting process, which combines the matte smelting and converting steps in one continuous process, will be discussed in a …
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Journal Article: New Slag for Nickel Matte Smelting Process and Subsequent Fe Extraction ... This article suggests that the slag for nickel smelting is adjusted by increasing the amount of lime, partly instead of quartz, to form liable reduction compounds for subsequent Fe extraction. Based on the thermodynamic analysis and …
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Metallurgy - Matte Smelting, Refining, Alloying: The primary purpose of matte smelting is to melt and recombine the charge into a homogeneous matte of metallic copper, nickel, cobalt, and iron sulfides and to give an iron and silicon oxide slag. It is done in many types of furnace on both roasted or unroasted sulfide feed material. The reverberatory furnace …
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The two main processing methods for laterite ores are smelting and High-Pressure Acid Leaching (HPAL). Smelting is used primarily on saprolite ores to obtain an iron-nickel alloy (ferronickel – FeNi, Nickel Pig Iron – NPI) while HPAL is used primarily to process limonite or for higher-purity end products.
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