Ferronickel from Spent Nickel Catalyst

1.

Title of Product/Design/Equipment.

Ferronickel from Spent Nickel Catalyst

2.

IPR Status

Patent/Abroad IPR Details

Patent Filed

3.

Application/Uses

Ni recovery

4.

Salient Technical Feature including Competing Feature

A simple smelting process is developed for recovery of nickel as ferronickel of various grades from different nickel catalysts containing nickel in the range, 8 -18%. By controlling the parameters and the process techniques, ferronickel of 20 - 75% Ni grade have been produced with > 90% Ni recovery. The process consists of mixing the spent catalyst with additives, heating and reducing the mixture to get ferro-nickel

5.

Level/Scale of Development

10 kg spent catalyst per batch smelting

6.

Environmental Consideration

Per ton of spent catalyst smelting would produce about 250 kg of C0₂ gas. The slag generated is non-toxic and can be dumped

7.

Status of Commercialization

Ready for commercialization

8.

Major Raw Material to be Utilized

Spent nickel catalyst, mill scale (iron oxide), coke etc.

9.

Major Raw Plant Equipment and Machinery Required

Grinding and palletizing, Smelting furnace

10.

Techno-Economics

For a 10 MT/month capacity plant;

Capital cost is ~90 L (excluding land & shed) Recurring Expenditure -Rs. 4.0 Lakhs/month (excluding the cost of spent catalyst).

11.

Technology Package

Process-Know-how, (b) Details of equipment, (c) Plant Layout and (d) Quality Assurance Methods