Processing nickel ore into ferronickel involves several steps, each requiring specialized machinery. Below is an overview of the key stages and the machines used in nickel ore to ferronickel processing:
1. Ore Preparation (Crushing & Grinding)
– Jaw Crusher – Primary crushing of raw nickel ore (laterite or sulfides).
– Cone Crusher / Impact Crusher – Secondary crushing for finer particles.
– Ball Mill / SAG Mill – Grinding the ore into a fine powder for further processing.
– Screening & Classification (Vibrating Screens, Hydrocyclones) – Separating particles by size.
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2. Beneficiation (Upgrading Nickel Content)
– Magnetic Separator – Used for separating magnetic minerals from non-magnetic ones (especially in sulfide ores).
– Flotation Machine – For sulfide ores to separate nickel-bearing minerals from gangue.
– Gravity Separation (Spiral Classifiers, Shaking Tables) – Used in laterite ore processing to remove silica and other impurities.
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3. Drying & Calcination (For Laterite Ores)
– Rotary Dryer – Reduces moisture content in lateritic nickel ore.
– Rotary Kiln / Fluidized Bed Roaster – Removes chemically bound water and pre-reduces the ore before smelting.
4. Smelting (Reduction to Ferronickel)
– Electric Arc Furnace (EAF) / Submerged Arc Furnace (SAF) – High-temperature smelting to reduce nickel oxide into ferronickel (~20-40% Ni).
– Coke or coal is used as a reducing agent.
– Lime or dolomite is added as flux to remove impurities as slag.
– Converter Furnace – Further refining to adjust carbon, sulfur, and phosphorus levels.
5. Refining & Casting
– Ladle Refining Furnace (LRF) – Adjusts final composition of ferronickel.
– Continuous Casting Machine – Forms ferronickel ingots or granules for commercial use.
6. Waste & Byproduct Handling
– Slag Granulation System – Processes slag from smelting for disposal or reuse.
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