Abstract
Due to its emerging role in the clean energy transition and green technologies, as well as its established applications in infrastructure, chemical manufacturing, and food production, the demand for nickel is increasing. At the same time, high-grade sulphide nickel ores are becoming increasingly scarce, shifting nickel production toward laterite resources. Laterite processing routes to produce advanced Ni products that not only mitigate geopolitical risks but are also environmentally and economically sustainable should be developed. The aim of this study is to evaluate the viability of processing European laterite ore to produce nickel oxide, which will then be used as raw material for the production of Ni superalloys via the innovative metallothermic velocity melting (MVM) process. First, the ore will be characterized with regard to its bulk chemistry, mineralogy, phase composition, moisture content, and thermal behavior. Two approaches, pyrometallurgical treatment and the modified Caron process, will be explored. In the first approach, the dried ore undergoes calcination, molten-state reduction, followed by sulphidization and roasting. In the modified Caron process, the solid ore will be reduced in laboratory fluidized-bed roasters before undergoing ammoniacal leaching. The technical feasibility of the two production routes will be evaluated using thermodynamic modeling, experimental trials, and life-cycle assessment. Furthermore, the findings will be used to identify opportunities for process optimization and to serve as a basis for the development of a more sustainable extraction method, e.g., by using hydrogen in place of carbon-based reductants in molten-state reduction and using deep eutectic solvents (green solvents) as a leachant.