This article presents the results of laboratory studies on the smelting of nickel–chromium-containing ferroalloys from low-grade nickel ores from Kazakhstan. X-ray phase analysis was performed on raw materials, which included quartz, nontronite, chromium metahydroxide, goethite, magnetite, iron chromite, and nickel (II) silicate. The reduction reactions of metal oxides with carbon and carbon monoxide were studied as the temperature increased. Experimental smelting was carried out in a Tammann furnace at 1500–1550 °C using three types of reducing agent: RK coke, as well as its mixtures with low-ash Shubarkol coal, in ratios of 75:25 and 50:50. The second option demonstrated the highest economic efficiency, achieving a 91% nickel recovery rate, reduced coke consumption, and a slag-to-metal ratio of 3.07. Chemical analysis showed that the nickel content in the obtained alloys ranged from 2.5% to 6.5%, while chromium content ranged from 2.6% to 4.5%. X-ray phase analysis confirmed the presence of Fe₂Ni_0.6Si, Fe₅Si₃, and Fe₂CrSi phases in the alloy structure. Local element concentrations varied within the following ranges: Fe—55–59%, Ni—2–10%, Cr—2–7%, and Si—29–35%. The results of this study confirmed the feasibility of producing a nickel–chromium-containing alloy with a nickel content of 2–10% and a chromium content of 2–7%.

In the process of producing ferroalloys, a large amount of secondary raw materials is formed, including slag, aspiration dusts and sludge. The recycling of secondary raw materials can create resources and bring environmental and economic benefits. Wet secondary raw materials (WSRMs) are characterized by a high chromium oxide content (averaging 24%), but due to their high moisture levels, they cannot be directly used in arc furnaces. As a strategic approach, mixing WSRMs with drier, more chromium-rich dusts (up to 45% Cr₂O₃) has been proposed. This not only reduces the overall moisture content of the mixture but also enhances the metallurgical value of the charge material. This paper presents the results of laboratory studies on the agglomeration of secondary wet raw materials using briquetting, extrusion and pelletizing methods. The main factors influencing the quality of the resulting product were analyzed, including the method of agglomeration, the composition of the mixture, as well as the type and dosage of the binder component. The strength characteristics of the finished agglomerated samples were evaluated in terms of resistance to splitting, impact loads and falling. Notably, the selected binders are organic and polymer substances capable of complete combustion under metallurgical smelting conditions.

Processing of nickel ores is a key aspect of modern metallurgy due to the growing demand for nickel in stainless steel, battery production, and advanced materials. The depletion of high-grade sulfide ores has shifted attention toward oxidized (lateritic) nickel ores, which are characterized by complex mineralogy and low metal content. This study presents a comparative review of major processing technologies, including pyrometallurgical, hydrometallurgical, and hybrid approaches, with particular emphasis on their applicability to Kazakhstan’s limonitic laterites with high iron and low nickel content. The analysis shows that the most suitable processing routes for such ores include atmospheric acid leaching (AL), high-pressure acid leaching (HPAL), metallothermic reduction, and combined flowsheets integrating thermal and leaching stages. Among these, AL and hybrid approaches are identified as the most promising under resource-constrained conditions. Despite recent technological progress, challenges remain related to energy consumption, economic feasibility, and environmental impact. The study highlights the importance of developing energy-efficient and low-carbon technologies, including hydrogen-based reduction, and provides practical recommendations for selecting and adapting processing methods for Kazakhstan.

This article discusses the development of a technology for producing nickel- and chromium-containing ferroalloy through the carbothermic reduction of low-grade ores from the Batamsha deposit. Thermodynamic modeling of phase formation was carried out using the Chemistry 10 software package, along with a series of pilot-scale smelting experiments in a submerged arc furnace. The influence of technological parameters, particularly slag basicity, on the distribution of nickel and chromium in the alloy was studied. The results of an X-ray phase analysis confirmed the modeling conclusions, revealing the presence of nickel and chromium silicide phases. The proposed technology demonstrated a high metal recovery rate and process stability, indicating its potential for industrial application in Kazakhstan.

вердофазного восстановления никелевой латеритной руды месторождения «Батамша» с использованием программного комплекса «HSC Chemistry 10». Рентгенофазовым анализом был определен фазовый состав никелевой руды: 1,43% NiO, 5,2% Fe₂O₃, 9,4% Fe₃O₄, 6% FeO·OH, 5,4% Fe₂SiO₄, 0,27% FeS, 4,2% MgSiO₃, 12,4% Mg₃Si₂O₅(OH)₄, 35,1% CaAl₂Si₂O₈, 17,8% SiO₂ и 2,8% CaCO₃. Полученные данные были использованы для расчёта молярного состава никелевой руды, необходимого для определения количества молей компонентов, участвующих в реакции восстановления оксидных соединений в руде, с применением программного комплекса «HSC Chemistry 10». Термодинамика процесса восстановления изучена с применением модуля Equilibrium Composition, который осуществляет расчёт методом минимизации свободной энергии Гиббса, что позволяет определить равновесные составы взаимодействующих фаз. Изучались процессы воостановления никелевой латеритной руды монооксидом углерода и его смесью с водородом в соотношениях (1:1), (1:2) и (1:3). Исследование с использованием монооксида углерода в качестве восстановителя показало, что восстановление никеля начинается при 440 °C, полное восстановление достигается при расходе восстановителя 1,1 моль при температуре 900 ºС. Исследование показали, что добавление водорода к СО значительно снижает температуру начала восстановления и полного восстановления никеля (с 440/900 °C до 340/700 °C), а также требуемый расход восстановителя. Восстановление железа во всех исследованиях начиналось при 440 °C, что указывает на селективное восстановление никеля при применении смесей СО с водородом. Восстановительную смесь CO+H₂ в соотношении 1:2 можно считать оптимальным с точки зрения баланса между эффективностью восстановления и экономическими параметрами процесса. Полученные результаты свидетельствуют о перспективности применения водородсодержащих восстановительных смесей для повышения эффективности процесса извлечения никеля из латеритных руд, однако оптимальный состав смеси зависит от специфических характеристик руды и технологических условий. Ключевые слова: латеритная никелевая руда, низкотемпературное селективное восстановление, водород, монооксид углерода, моделирование восстановления.