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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

Product SDS
‘SAIRSET A wet, air-setting, fireclay mortar
‘SAIRSET 3000 A high alumina air-setting mortar English
60DB® A 60% magnesia, burned brick English
ALADIN® 80 An 80% alumina brick
AUREX® 30 SR An alumina-chrome brick with 30% chrome, designed for thermal shock resistance English
CLIPPER® DP A super duty fireclay brick
GREENKLEEN®-60 PLUS A 60% alumina, andalusite containing low cement castable
GREENTHERM 23 LI A 2300°F rated insulating firebrick
GREENTHERM 26 LI A 2600°F rated insulating firebrick
GREENTHERM 28 LI A 2800°F rated insulating firebrick
HP-CAST ® ULTRA C10 A high purity alumina, 10% chrome containing, ultra-low cement castable English
KALA® A 50% alumina brick
KRUZITE®-70 A 70% alumina brick
KX-99® A high fired, super duty fireclay brick
KX-99®-BF A high fired, super duty fireclay brick
NARMAG® 50 DBRG A magnesia chrome burned brick English
NARMAG® 60 CU A magnesia chrome burned brick English
NARMAG® 60 DB A magnesia chrome burned brick English
NARMAG® 6260 A magnesia chrome burned brick English
NARMAG® 80 DB A magnesia chrome burned brick English
NARMAG® FG A magnesia chrome burned brick English
NARMAG® FG CASTABLE An ultra-low cement, magnesia and chrome containing castable English
NARMAG® FG FINE MORTAR DRY A magnesia chrome mortar English
NARMAG® FG GUN A magnesia chrome gunning mix English
NARMAG® FG RAM MIX A magnesia chrome ram mix English
NARMAG® FG-HS CASTABLE A magnesia chrome castable English
NARMAG® HNF 27 A burned, magnesia chrome brick English
NARMAG® HNF 31 A burned, magnesia chrome brick English
PLASTECH® RUBY® An alumina-chromium, phosphate bonded refractory plastic
PLASTECH® RUBY® 20 A 20% chrome, phosphate bonded refractory plastic English
RUBY® An alumina-chrome brick with 10% chrome English
RUBY® BOND An air-setting alumina chrome mortar English
RUBY® MORTAR An alumina-chrome, phosphate bonded mortar English
RUBY® RAMMING MIX A phosphate-bonded, alumina-chromium ram mix English
RUBY® SR An alumina-chrome brick with 10% chrome, designed for thermal shock resistance
SHAMROCK® 391-TR MORTAR An alumina-chrome mortar English
SHAMROCK® 392 DRY MORTAR A dry, phosphate bonded, alumina-chrome mortar
SHAMROCK® 392 MORTAR A chrome alumina mortar English
SHAMROCK® 394 DRY MORTAR A dry, heat-setting, alumina-chrome mortar
SHAMROCK® 493 CASTABLE A low-moisture, chromia-alumina castable
SUPER NARMAG® 142 A 60% magnesia, 20% chrome burned brick English
SUPER NARMAG® 145 A 60% magnesia, 20% chrome burned brick English
SUPER NARMAG® 148 CU A magnesia chrome burned brick designed for the Copper Industry English
SUPER NARMAG® FG A magnesia chrome burned brick English
THERMOLITH® A dry, air-setting, high-temperature, bonding mortar with chrome-ore base English

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