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direct reduction process of nickel ores using rotary kiln as

  • Direct Reduction of Limonitic Laterite Nickel Ore with ...

    The increasing demand for stainless steel and the scarcity of sulfide nickel ore affect the increase of laterite nickel ore processing. One of the processes that has been proven can be applied to process laterite nickel ore is direct reduction. In the direct reduction, the reduction atmosphere was adjusted by controlling the volume of CO and CO2 from carbon source materials, such as coal ...

  • STUDY ON REDUCTION OF IRON ORE CONCENTRATE IN ROTARY KILN ...

    In this research, prior pellets preparation a magnetic oxidation process on iron ore concentrate was also conducted and changed the magnetite into hematite. The reduction process on its pellets produced 94.15% metallization at 1,100°C, and the DRI contained 97.85% of Fe total , 85.32% of Fe metal and 5.35% of Fe oxides.

  • Nickel and its extraction - SlideShare

    May 03, 2018· A rotary dryer is typically used to remove free moisture. Preliminary Reduction Once ore has been dried, it is processed in a large-scale rotary kiln to remove chemically bound moisture, as well as the oxide component of the ore.

  • THE FUTURE OF DIRECT REDUCTION PROCESSES M. N.

    The application of rotary kiln for ore reduction is not new; it had been used long back in the Krupp-renn process. The large rotary kiln DR units installed recently were initially faced with TABLE 1 List of Direct Reduction Plants in Operation and under Construction Product Process Country Place Reduction unit Total capacity (metric ton)

  • Selective Reduction of Laterite Nickel Ore

    to 1300°C, the phase of saprolitic nickel ore changes into a complex mineral. The mineral is dominated by olivine (Mg 0.5Fe 0.5) 2SiO 4. 29) 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

  • ROTARY KILN REDUCTION OF LIMONITIC ORES -

    We claim 1. In the countercurrent fuel fired rotary kiln process for selectively reducing metal values from the group consisting of nickel, cobalt and copper contained in a lateritic ore wherein ore fed to the rotary kiln is passed successively through a preheat zone and through a reduction zone, and reduced ore is discharged from said kiln, the improvement for maintaining within the reduction ...

  • ROTARY KILNS - Thomasnet

    the rotary kiln. Direct-fired rotary kilns can operate in either the co-current mode, where combustion gases and solids move in ... Unlike an unheated coating process, here, a rotary kiln heats the coating material to just below liquefaction ... Reduction roasting is the removal of oxygen from a component of an ore usually by using Carbon Monoxide

  • tunnel kiln design for reduction of ores

    direct reduction of nickel ores in rotary kiln « BINQ Mining. Direct reduction of iron ore by one or more processes un- der study by .. ore in a vertical shaft furnace, a rotary or tunnel kiln, or other types of hearth or grate furnaces to . and ores containing titanium, nickel,

  • Rotary kiln - Wikipedia

    History. The rotary kiln was invented in 1873 by Frederick Ransome.. Kiln shell. This is made from rolled mild steel plate, usually between 15 and 30 mm thick, welded to form a cylinder which may be up to 230 m in length and up to 6 m in diameter.. Upper limits on diameter are set by the tendency of the shell to deform under its own weight to an oval cross section, with consequent flexure ...

  • Modelling and optimization of a rotary kiln direct ...

    In the case of a generic iron ore reduction kiln (Figure 1), Table I provides an overview of the parameters (and ranges) that are considered. Modelling and optimization of a rotary kiln direct reduction process by H.P. Kritzinger* and T.C. Kingsley* Synopsis Rotary kilns are used for a variety of mineral processing operations. Hatch

  • direct reduction of nickel ores in rotary kiln

    direct reduction nickel ore Grinding Mill China. In the direct reduction of lateritic nickel ore by Rotary Kiln, we made great successes and have already done ... Request Quotation. Direct reduction of garnierite ore for production of ferro-nickel with a rotary kiln at Nippon Yakin Kogyo Co., Ltd., Oheyama Works. Tetsuya Watanabe, Request ...

  • Direct Reduction Process Description | HeatTreatConsortium

    Process Description R&D Trends. In a direct reduction process, lump iron oxide pellets and/or lump iron ore, are reduced (oxygen removed) by a reducing gas, producing direct reduced iron (DRI). If the cooling stage is omitted, the DRI can be immediately briquetted into hot briquetted iron (HBI).

  • DRI production | International Iron Metallics Association

    The Finmet / Finored gas-based process utilizes iron ore fines as feedstock. The SLRN coal-based rotary kiln process uses lump ore and, increasingly, pellets as feedstock. There are variants of these processes which are described on the websites of the various technology providers. Midrex® process. Midrex® direct reduction process flowsheet ...

  • Damring Formation During Rotary Kiln Chromite Pre ...

    Chromite pre-reduction applied on an industrial scale takes place in a counter current rotary kiln. Pellets are fed into the kiln and heated to approximately 1573 K (1300 C). Cross- and longitudinal sectional cut illus-trations of a typical rotary kiln with pelletized feed that is used in the chromite pre-reduction process are presented in ...

  • CN101403043A - Method for producing ferronickel granule ...

    The invention relates to a method for producing ferronickel granules from nickel ore, in particular to a method that nickeliferous laterite ore is directly reduced to produce ferronickel granules in a rotary kiln, belonging to the technical field of metallurgy and chemical industry. The method comprises the following steps: nickeliferous laterite ore is crushed and milled, then carbonaceous ...

  • Direct Nickel Process Breakthrough Technology

    Direct Nickel has developed a game changing pro cess for extracting nickel from laterite deposits. It will position Direct Nickel as one of the lowest cash cost producers in the global nickel industry in the next 5 years. The Process offers unparalleled co st efficiency, capital savi ngs and environmental benefits.

  • Ring Formation in the Smelting of Saprolite Ni-ore in a ...

    That is generally smelted by the Elkem process to the ferro-nickel, which is mostly used as a nickel source for stainless steel. The calcination to around 1000°C by the rotary kiln provides drying and pre-reduction of ores, the calcinated product being subsequently charged into the

  • Direct Reduction Process - an overview | ScienceDirect Topics

    The direct reduction processes in combination with the melting of directly reduced iron to produce steel in the EAF offer an alternative to the BF-BOF route. The basis of the direct reduction process is that solid sponge iron is produced by removing oxygen from the ore in a shaft furnace, rotary kiln furnace or fluidised bed. Sponge iron can be ...

  • Rotary Kiln Design: Direct Fired vs. Indirect Fired

    Direct-fired rotary kilns rely on direct contact between the process gas and the material in order to heat the material to the specified temperature. Direct-fired kilns can be either of the co-current design, or counter current design, referring to the direction that the process gas flows through the

  • THE KRUPP SPONGE IRON PROCESS PRODUCTION AND

    derable number of full-scale rotary kiln instal-lations have been successfully delivered in the past (4 kilns, 4.2 m dia., 110 m long, for the Essen-Borbeck Renn plant; 2 kilns, 4.2 m dia., 90 m long and 1 kiln, 5.2 m dia., 90 m long, for the pre-reduction of nickel ores at Larymna, Greece; 1 kiln, 4.2 m dia., 60 m long, for a Waelz

  • Process update Direct reduction process using fines and ...

    There is no direct reduction process for manganese , although partial prereduction of Þne ores is carried out in the manufacture of Mn metal by electrolysis.6 The refractoriness of Mn oxide means that the temperatures required for reasonable rates of reduction in a direct process would be above the melting point of the Mn carbide alloy.

  • Direct Reduced Iron and its Production Processes IspatGuru

    Mar 16, 2013· The coal based process uses any one of the four types of reactors for the reduction reaction. These reactors are (i) rotary kiln, (ii) shaft furnace, (iii) fluidized bed reactor, and (iv) rotary hearth furnace. Rotary kiln is the most popular reactor for the coal based process. The principle of the direct reduction of iron ore is shown in Fig 1.

  • Reduction process of low-grade nickel laterite ...

    The process of using a rotary kiln-electric furnace (RKEF) is the main technology used globally for the treatment of lateritic nickel ores for the production of ferronickel . In this process, ore fines are generated and emitted into the atmosphere.

  • CN106636625A - Method for producing ferronickel by ...

    The invention provides a method for producing ferronickel by adopting a rotary kiln direct reduction-RKEF (Rotary Kiln-Electric Furnace) combination method. The method comprises the following steps: drying a laterite nickel ore for later use; crushing and screening an appropriate amount of the dried laterite nickel ore, and then mixing the screened laterite nickel ore with a carbonaceous ...

  • direct reduction of garnierite ore for production of ferro ...

    Patent CNU. Process for RKEF philippines Sulawesi nickel laterite nickel ore production of iron kiln, , is a direct reduction method using a rotary kiln , In garnierite nickel.

  • direct reduction nickel ore - garden-state

    Direct Reduction Process Of Nickel Ores Using Rotary Kiln As The Main Equipment We are a large-scale manufacturer specializing in producing various mining machines including different types ofsandandgravel equipment,milling equipment,mineral processing

  • Prospects for Coal-based Direct Reduction Process

    process, heat transfer occurs efficiently by radiation, with much less risk of reduction fragmentation. Thus, this process would be more advantageous than any conventional process using a rotary kiln or a shaft furnace. In the early 1960s, Midland Ross Corp., the predecessor of MIDREX Technologies, started developing a process called "HEATFAST,"

  • Moisture Reduction in a Rotary Kiln - FEECO International Inc.

    Although rotary kilns are designed to be used for driving a chemical reaction, an issue that often comes up in the processing of a material is when to draw the excess moisture from the feedstock.. Many times, there is an excess of moisture that needs to be removed from the material before it is converted in the rotary kiln, and people are faced with a decision: buy another piece of equipment ...

  • SLRN process - Outotec

    The process principles are the basis for numerous rotary kiln plants and still represent the dominant technology for the direct reduction of lump ore or pellets using coal. Operates with the widest range of iron-bearing materials, such as pellets, lump ore, beach sand, ilmenite and also iron ore

  • Factors Affecting the Increase in the Pre-reduction Scale ...

    rotary kilns increases by 40% in comparison to the industrial cases. Keywords: pre-reduction, iron-nickel, ore, rotary kiln, average, calcine, percentage. Introduction The metallurgical process in the new Foundry of the new Ferronikel in Drenas, is realized by a variety of ores both imported and local. A few types are used as fuel.

  • ore rotary kiln production line project

    Coal based Direct Reduction Rotary Kiln Process IspatGuru The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in predetermined ratio. The rotary kiln is slightly inclined at an angle 2.5 degree and rotated by AC variable speed motor at a variable speed ranging from 0.2 rpm (revolutions per ...

  • PILOT PLANT PRODUCTION OF FERRONICKEL FROM

    Nickel laterite ores have high moisture contents (typically up to 40%) as well as chemically bonded water in the hydroxide form. Dehydration as a minimum, and some pre-reduction of the ore in a rotary kiln is used to optimize the utilization of electric energy for smelting operations in the conventional submerged-arc furnace process. During the ...

  • Direct reduction of garnierite ore for production of ferro ...

    May 01, 1987· Direct reduction of garnierits ore for production of ferro-nickel with a rotary kiln at Nippon Yakin Kogyo Co., Ltd., Oheyama Works. Int. J. Miner. Process., 19: 173-187. During World War II, the Nippon Yakin Kogyo Co., Ltd. produced sponge iron with the Krupp- Renn process at the OheyAmA Works from laterite ore mined at the nearby OheyRma Mine.

  • Modelling and optimization of a rotary kiln direct ...

    Modelling and optimization of a rotary kiln direct reduction process 55 Figure 3. Kiln temperature distribution for the base case The feed material (bed) enters the kiln at ambient temperature and rapidly heats up due to the hot gas in the freeboard.

  • direct reduction of nickel ores in rotary kiln

    A Pilot-Plant Scale Test of Coal-Based Rotary Kiln Direct ... Apr 18, 1972· Directed to the reduction of nickel-containing lateritic ores in a rotary kiln at high production rates to achieve selective reduction of nickel contained in the ore wherein the ore is preheated to at least about 1,000° F. in a preheating zone in the kiln and is maintained at at least this temperature while it ...

  • Preparation of ferronickel from nickel laterite via coal ...

    Jul 11, 2018· 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.

  • Nickel processing - Extraction and refining | Britannica

    Nickel processing - Nickel processing - Extraction and refining: The extraction of nickel from ore follows much the same route as copper, and indeed, in a number of cases, similar processes and equipment are used. The major differences in equipment are the use of higher-temperature refractories and the increased cooling required to accommodate the higher operating temperatures in nickel ...

  • Production of Direct Reduced Iron in Rotary Hearth Furnace

    Sep 23, 2011· References<br />[1] S. Halder and R.J. Fruehan Reduction of Iron-Oxide-Carbon Composites: Part I. Estimation of the Rate Constants Metallurgical and Materials Transactions B, 2008, Volume 39, Number 6, Pages 784-795<br />[2] I. F. Kurunov Metallurgist, The Direct Production of Iron and Alternatives to the Blast Furnace in Iron Metallurgy for ...