New Nickel Value Chain from Laterite to Stainless Steel – Outotec Ferrochromenickel Process

"Approximately two thirds of annual nickel production is used as a raw material in the making of stainless steel, and about 60% of these nickel products are in the form of metallic nickel such as nickel cathode or briquettes. In the stainless-steel production process nickel is blended with iron and chrome-based raw materials, and metallic nickel is typically only required for final steel fine-tuning. Outotec offers a new FeCrNi technology to enhance the nickel value chain for stainless steel producers. This involves the use of an HPAL-based intermediate nickel product (e.g., mixed hydroxides or NiO) as raw material in the Outotec FeCrNi process, for the production of a FeCrNi Master Alloy. The new process, designated as the FeCrNi process, offers multiple benefits compared to existing technologies such as: higher tolerance for impurities in the HPAL intermediate product, avoiding the need for further nickel refining, and the improved recovery of all metals in the FeCr process. The complete new FeCrNi value chain is based on proven technologies such as HPAL and the Outotec FeCr-process. This new innovative and promising value chain offers improved efficiencies for the HPAL based nickel production process combined with excellent sustainability aspects.INTRODUCTION In today’s global economy there is a constant need to improve the efficiency and sustainability of the metals production. The requirements for modern metal refining are tightening and cost efficient, safe and sustainable operation is the precondition for all investment. Outotec is offering now a novel way to combine FeCr and Nickel production to create a completely new value chain to source nickel to stainless steel. BACKGROUND Nickel The current nickel mine production is in the level of 2,000 tons annually and it is split 44% from sulphide based deposits and 56% from laterite deposits (Figure 1). Most (40%) of the nickel is refined to pure nickel metal whereas other products are FeNi (19%) and Nickel Pig Iron NPI (20%) (Roskill). The remaining part, roughly 21%, is nickel chemicals and intermediates. Most of the new investments in nickel are in the direct shipping of laterite to produce nickel pig iron. HPAL process is considered in few projects but no major HPAL projects have been started since the Ambatovy plant in Madagascar. Ambatovy reached the commercial production in 2014. The main primary nickel used is stainless steel manufacturing. In the year 2016 about 68% (~1,360 kt) of primary nickel production was used in stainless steel."