Дослідження та впровадження технології низького відновлення заліза в умовах ПФК (Україна)

The study focuses on the development and industrial implementation of low iron reduction technology for the production of crude ferronickel in high‑power ore‑thermal furnaces, followed by secondary refining. The aim is to improve product quality, reduce energy consumption, and enhance the competitiveness of ferronickel production. Methodology. More than 300 pilot‑industrial tests of secondary refining of crude ferronickel with low silicon content were conducted under industrial conditions at the Pobuzhsky Ferronickel Plant. The methodology included systematic sampling of metal and slag, temperature measurements, staged refining operations with lime, soda, aluminum, and ferrosilicon additions, as well as monitoring of current loads and furnace operating parameters. Findings. The developed technology enabled the production of ferronickel with nickel content up to 60%, while maintaining extremely low levels of silicon and carbon (<0.1%). Effective desulfurization and impurity removal (S, C, P) were achieved without the use of a ladle‑furnace unit. The process demonstrated a stable decrease in specific electricity consumption with increasing furnace power and iron content in ore, confirming both technological and economic efficiency. Originality. Unlike traditional high iron reduction technology, which produces ferronickel with elevated silicon and carbon levels, the proposed low iron reduction approach ensures the production of high‑grade ferronickel suitable for direct refining. The originality lies in the combined refining scheme, integrating ladle and converter operations under industrial conditions, providing a practical solution in the absence of a ladle‑furnace unit. Practical value. The implementation of the technology at the Pobuzhsky Ferronickel Plant resulted in competitive ferronickel products, enhanced export potential, and reduced production costs. The economic efficiency is reflected in lowering the cost of commercial ferronickel to approximately 1000 USD/t, positioning the enterprise among the leading metallurgical producers in Ukraine in terms of foreign currency revenues.