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<p>The enhancement of nickel recovery and grade from laterite ores with high silica content has until recently been a challenge. This work has investigated the optimization of selective carbothermic reduction in laterite nickel ore by the integration of sodium hydroxide (NaOH) as a new binding agent. The experimental design systematically combined saprolite ore (1.81&#xa0;wt.% Ni) with sub-bituminous coal (2&#xa0;wt.%) under controlled conditions. The effects of NaOH dosages (0&#xa0;wt.%, 5&#xa0;wt.%, and 10&#xa0;wt.%) and reduction temperature (900–1100°C) on extraction efficiency and phase transformation have been thoroughly investigated. Comprehensive characterization using DTA/TGA, SEM-EDS, ICP, and XRD analyses has revealed the mechanisms underlying the reduction process. The results of the experiments indicated that increasing the temperature to 1100°C and employing 10&#xa0;wt.% NaOH significantly decomposed the saprolite ore, yielding forsterite, fayalite, nickel (Ni) metal, and ferronickel (FeNi) alloys, thus enhancing nickel recovery and grade. The morphology of Ni metal and FeNi alloys appeared as porous aggregates encased inside the silicate compound matrix. The nickel recovery increased to 87.42%, while the nickel grade improved to 12.07%. These findings provide valuable insights into the development of more efficient and selective nickel extraction processes from laterite ores.</p>

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NaOH-assisted Carbothermic Reduction for High-Grade Ferronickel Production: A Study on Selective Reduction and Phase Transformation of Saprolite Ore

  • 期刊论文

  • 发表日期：

    2026年2月26日

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  • Iwan Setiawan,
  • Latifa Hanum Lalasari,
  • Januar Irawan,
  • Eko Sulistiyono,
  • Tri Arini,
  • Lia Andriyah,
  • Ariyo Suharyanto,
  • F. Firdiyono,
  • Sri Harjanto

摘要

The enhancement of nickel recovery and grade from laterite ores with high silica content has until recently been a challenge. This work has investigated the optimization of selective carbothermic reduction in laterite nickel ore by the integration of sodium hydroxide (NaOH) as a new binding agent. The experimental design systematically combined saprolite ore (1.81 wt.% Ni) with sub-bituminous coal (2 wt.%) under controlled conditions. The effects of NaOH dosages (0 wt.%, 5 wt.%, and 10 wt.%) and reduction temperature (900–1100°C) on extraction efficiency and phase transformation have been thoroughly investigated. Comprehensive characterization using DTA/TGA, SEM-EDS, ICP, and XRD analyses has revealed the mechanisms underlying the reduction process. The results of the experiments indicated that increasing the temperature to 1100°C and employing 10 wt.% NaOH significantly decomposed the saprolite ore, yielding forsterite, fayalite, nickel (Ni) metal, and ferronickel (FeNi) alloys, thus enhancing nickel recovery and grade. The morphology of Ni metal and FeNi alloys appeared as porous aggregates encased inside the silicate compound matrix. The nickel recovery increased to 87.42%, while the nickel grade improved to 12.07%. These findings provide valuable insights into the development of more efficient and selective nickel extraction processes from laterite ores.