Production of ferronickel from mill-scale via metallothermic process

In this study, the production of ferronickel (Fe-Ni), which is an iron-based alloy, was carried out by aluminothermic methods. Mill scale obtained from continuous casting process was used as starting material. Mill scale is oxidized layers of steel alloys containing iron oxide with +2 and +3 values, it is formed on the surface of slabs and billets during annealing process at integrated iron and steel plants. In the metallothermic experiments, effect of aluminium (Al) powder addition to various ratios of starting oxide powders [mill scale (Fe, Fe2O3, FeO, Fe3O4), NiO] on metal recovery and alloy compositions were investigated. Before the experiments, reduction conditions were simulated via FactSage 6.4 database and convenient stoichiometric ratios were determined. Samples were characterized by chemical analysis (AAS), XRD, XRF and optical microscopy techniques. Highest metal recovery was obtained as 81.24% by using 110% stoichiometric Al containing mixture. © 2020, TUBITAK. All rights reserved.