Approximately two thirds of annual nickel production is used as a raw material in the manufacture of stainless steel, and about 60% of these nickel products are in the form of metallic nickel such as nickel cathode or briquettes. In the stainless steel production process, nickel is blended with iron and chrome-based raw materials, and metallic nickel is typically only required for final steel fine-tuning. Outotec introduces a new FeCrNi technology to enhance the nickel value chain for stainless steel producers. This involves the use of a high-pressure acid leach (HPAL) based intermediate nickel product (e.g., mixed hydroxides or NiO) as raw material in the new Outotec FeCrNi process, for the production of a FeCrNi master alloy. The new process provides multiple benefits compared to existing technologies, such as higher tolerance for impurities in the HPAL intermediate product, avoiding the need for further nickel refining, and the improved recovery of all metals in the FeCr process. The complete new FeCrNi value chain is based on proven technologies such as HPAL and the Outotec FeCr process. This innovative and promising value chain offers improved efficiencies for the HPAL-based nickel production process, as well as excellent sustainability benefits.

1. Value Chain of
Nickel Laterite

2. Value Chain
Ores
Process
Products
Nickel Laterite
HGSO
Ni ≥ 1,8%
±32,81 $/ton ore
±1,823 $/ton Ni eq.
LGSO
Ni 1,5 - 1,7%
±26,09 $/ton ore
±1,631 $/ton Ni eq.
Limonite
Ni 1,1 - 1,4%
±17,46 $/ton ore
±1,343 $/ton Ni eq.
Pyrometallurgy
(RKEF)
Total cost ±10,856 $/ton Ni
Pyrometallurgy
(Blast Furnace / RKEF)
Total cost ±10,624 $/ton Ni
Hydrometallurgy
(HPAL)
Total cost ±6,391 $/ton Ni
Ferronickel
Ni ±20%
±13,637 $/ton Ni eq.
Added value ±7,5x
Nickel Pig Iron
Ni ±10%
±11,709 $/ton Ni eq.
Added value ±7,2x
Nickel Matte
Ni ±70%
±12,673 $/ton Ni eq.
Added value ±7x
MHP
Ni ±40%
±11,291 $/ton Ni eq.
Added value ±8,4x
Hydro-Pyro metallurgy
(Caron)
Total cost ±7,669 $/ton Ni
Nickel Oxide
Ni ±75%
±11,020 $/ton Ni eq.
Added value ±8,2x
Stainless Steel Precursor
Batteries
MSP
Ni ±50%
±12,460 S/ton Ni eq.
Added value ±9,3x
Nickel Sulfate
Ni ±22%
±13,775 $/ton Ni eq.
Added value ±10,2x

3. Value Chain
Blast Furnace
For LGSO
• Drying
• Sintering
• Blast Furnace
• Total Cost 10,624 $/ton
Ni eq.

4. Value Chain
Rotary Kiln – Electric Furnace
For HGSO
• Rotary Dryer
• Rotary Kiln
• Electric Furnace
• Converter
• Total Cost 10,856 $/ton Ni eq.

5. Value Chain
Caron Process
For Limonite
• Reduction Kiln
• Leaching
• Precipitation
• Calcination Kiln
• Total Cost 7,669 $/ton
Ni eq.

6. Value Chain
HPAL Process
For Limonite
• High Pressure Acid Leaching
• Counter Current Digestion
• Precipitation
• Total Cost 6,391 $/ton Ni eq.

7. THANK YOU