Evaluation of Binderless Briquettes as Potential Feed for the Electric Arc Furnaces at Barro Alto, Brazil

Barro Alto processes nickel laterite ore using rotary kilns and six-in-line rectangular electric arc furnaces. This study evaluated the briquetting of ferronickel ore to reduce kiln fines, improve furnace charge permeability, and enhance process safety. Binderless briquettes were produced from screened ore at two size fractions (−6.3 mm and −12.5 mm), with moisture contents of 16% and 24%, cured under closed and open conditions. The physical and metallurgical properties of the briquettes were assessed using ISO standard tests. The results confirmed successful agglomeration of the ore into binderless briquettes. Screening the run-of-mine (ROM) ore improved the feed quality, increasing the NiO grade from 2.0% to 2.2% in the −6.3 mm fraction. The briquettes from the −6.3 mm ore at 16% moisture exhibited the highest green strength (559 N). Higher moisture content reduced the briquette strength and increased both the reduction disintegration and decrepitation indices. The decrepitation index increased from 0.33% to 0.61% for the −6.3 mm briquettes when the moisture increased from 16% to 24%. The reduction levels were 33.4% and 39.2% for −6.3 mm and −12.5 mm briquettes with 16% moisture, respectively. This study concludes that optimal performance was achieved using −6.3 mm ore, 16% moisture, and open curing, thereby balancing reduction efficiency and mechanical stability.