The Nickel Production Methods from Laterites and the Greek Ferronickel Production among Them

Primary world nickel production in 2020 was 2430.7 kt Ni; 69% (1677.7 kt) of them came from oxidized nickel ores (laterites) and 31% from sulfides. Production-wise, 87.7% of the 1677.7 kt came from pyrometallurgical and 12.3% from hydrometallurgical processes. For a long time, Fe-Ni had a 20–40% Ni analysis, but in 2006 a new Fe-Ni quality came into the scene. This is the nickel pig iron (NPI) with 2.5–5.5% Ni that comes from laterite smelting in the blast furnace (B/F). Eventually, the advantages of the R/K-E/F process led to its dispersion in China and Indonesia and resulted in an NPI production with 3–12% Ni. The NPI production in these two countries climbed from zero in 2000, to 1060 kt Ni in 2020 and also stainless-steel production from 5.5% to 67.2%, respectively, of the world’s SS production. The integration of Ni industry with SS production, the economy of scale, the low labor cost, the high Ni content of Indonesian laterite, and the loose environmental laws, reduced significantly the NPI production cost. The addition of SS and/or electric energy production units for cost reduction has been adapted from other Fe-Ni producers, as well. Hellenic Minerals in Cyprus after two years of successful industrial tests is in the commissioning state of a Heap Leaching-Solvent Extraction-Crystallizer (HL-SX-CR) unit for NiSO4.6H2O production. The high demand for Ni and NiSO4.6H2O in the last few years has changed the prospects of Ni laterite hydrometallurgical processing. Regarding the R/K-E/F process used in Greek Fe-Ni, it is characterized by its worldwide acceptance and reliability (more than 77% of world Fe-Ni production comes from this process). Other advantages are the use of all types of laterites and fuels, it has a high metallurgical recovery, and the plant has its own port. However, it is a high energy-consuming process, and it does not recover Co. The Greek laterite, in particular, has the lowest Ni% among global Fe-Ni producers and because of this, electric energy (MWh/t Ni) and wages (wages/t Ni) per ton of Ni are high, making Larco’s viability difficult. The only way to overcome the issue with specific electricity consumption is to enrich the local ores by blending them with imported high grade Ni ores. Other negatives were the excessive electric energy price it had to pay to a dominant energy supplier and the very frequent changes of its administration.