Ferronickel

The rotary kiln and electric furnace process has long been the most commonly employed method of recovering nickel from saprolitic laterite ores. Production improvements have been achieved over the years by the adoption of “shielded arc” smelting and the installation of water-cooled copper cooling elements in the furnace sidewalls. These pyrometallurgical processes are suited for ores containing predominately saprolite (1.5–3.0 percent nickel), with proportionately lower cobalt and iron content than limonitic ores. The nickel-cobalt ratio in the smelter feed is generally about 40. These ores are smelted to produce either ferronickel or matte.

The rotary reduction kilns are normally lined with CO-resistant castables that have sections of similarly CO-resistant brick. The electric ferronickel furnaces are designed with magnesia-and-tar-impregnated magnesia-based working linings. These are coupled with the installation of penetrative water-cooled copper elements in the furnace sidewalls and robust binding systems that provide long furnace life under intense smelting conditions. The final product can be produced by oxidation to a 75 percent FeNi using either Peirce-Smith or Kaldo rotary vessels lined with a combination of direct-bonded magnesia-chrome or rebonded fused-grain magnesia-chrome materials.

Products
Ferronickel

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Product Description
‘SAIRSET‘SAIRSET A wet, air-setting, fireclay mortar
‘SAIRSET 3000‘SAIRSET 3000 A high alumina air-setting mortar
60DB®60DB® A direct-bonded 60% magnesia, burned brick
ALADIN® 80ALADIN® 80 An 80% alumina brick
AUREX® 30 SRAUREX® 30 SR AUREX 30 SR is a 30% chromic oxide containing, high alumina refractory brick.
CLIPPER® DPCLIPPER® DP A super duty fireclay brick
CU-300CU-300 A powder flux for brass casting
GREENKLEEN®-60 PLUSGREENKLEEN®-60 PLUS A 60% alumina, andalusite containing low cement castable
GREENTHERM 23 LIGREENTHERM 23 LI A 2300°F rated insulating firebrick
GREENTHERM 26 LIGREENTHERM 26 LI A 2600°F rated insulating firebrick
GREENTHERM 28 LIGREENTHERM 28 LI A 2800°F rated insulating firebrick
HP-CAST ® ULTRA C10HP-CAST ® ULTRA C10 A high purity alumina, 10% chrome containing, ultra-low cement castable
KALA®KALA® A 50% alumina brick
KALA® HPC CHECKERSKALA® HPC CHECKERS A 50% alumina brick
KRUZITE®-70KRUZITE®-70 A 70% alumina brick
KX-99®KX-99® A high fired, super duty fireclay brick
KX-99®-BFKX-99®-BF A high fired, super duty fireclay brick
NARMAG 80 DB CHNNARMAG 80 DB CHN
NARMAG® 60 CUNARMAG® 60 CU A mixed-bond magnesia chrome burned brick for the copper industry.
NARMAG® 60 DBNARMAG® 60 DB A direct-bonded, 65% magnesia, 18% chromia burned brick
NARMAG® 95BNARMAG® 95B A 95% magnesia burned brick
NARMAG® FGNARMAG® FG A 19% chromia, rebonded fused-grain magnesia-chrome burned brick
NARMAG® FG CASTABLENARMAG® FG CASTABLE An ultra-low cement, magnesia and chrome containing castable
NARMAG® FG FINE MORTAR DRYNARMAG® FG FINE MORTAR DRY A magnesia chrome mortar
NARMAG® FG GUNNARMAG® FG GUN A magnesia chrome gunning mix
NARMAG® FG RAM MIXNARMAG® FG RAM MIX A magnesia chrome ram mix
NARMAG® FG-HS CASTABLENARMAG® FG-HS CASTABLE A magnesia chrome castable
NARMAG® HNF 27NARMAG® HNF 27 A 27% chrome-containing, magnesia-chrome burned brick
NARMAG® HNF 31NARMAG® HNF 31 A burned, magnesia chrome brick
PLASTECH® RUBY®PLASTECH® RUBY® An alumina-chromium, phosphate bonded refractory plastic
PLASTECH® RUBY® 20PLASTECH® RUBY® 20 A 20% chrome, phosphate bonded refractory plastic
RUBY®RUBY® An alumina-chrome brick with 10% chrome
RUBY® BONDRUBY® BOND An air-setting alumina chrome mortar
RUBY® MORTARRUBY® MORTAR An alumina-chrome, phosphate bonded mortar
RUBY® RAMMING MIXRUBY® RAMMING MIX A phosphate-bonded, alumina-chromium ram mix
RUBY® SRRUBY® SR An alumina-chrome brick with 10% chrome, designed for thermal shock resistance
SHAMROCK® 391-TR MORTARSHAMROCK® 391-TR MORTAR An alumina-chrome mortar
SHAMROCK® 392 DRY MORTARSHAMROCK® 392 DRY MORTAR A dry, phosphate bonded, alumina-chrome mortar
SHAMROCK® 392 MORTARSHAMROCK® 392 MORTAR A chrome alumina mortar
SHAMROCK® 394 DRY MORTARSHAMROCK® 394 DRY MORTAR A dry, heat-setting, alumina-chrome mortar
SHAMROCK® 493 CASTABLESHAMROCK® 493 CASTABLE A low-moisture, chromia-alumina castable
SHAMROCK® 885 PLASTICSHAMROCK® 885 PLASTIC Chrome-Alumina Plastic
SUPER NARMAG® 142SUPER NARMAG® 142 A 60% magnesia, 20% chrome burned brick
SUPER NARMAG® 145SUPER NARMAG® 145 A 60% magnesia, 20% chrome burned brick
SUPER NARMAG® 148 CUSUPER NARMAG® 148 CU A semi-rebonded magnesia chrome burned brick designed for the Copper Industry
SUPER NARMAG® FGSUPER NARMAG® FG A magnesia chrome burned brick
THERMOLITH®THERMOLITH® A dry, air-setting, high-temperature, bonding mortar with chrome-ore base

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