鎳為世界上重要金屬元素，目前廣泛應用於不鏽鋼製程。低品位(褐鐵型)紅土鎳礦於全世界蘊含量仍相當豐富，故提煉礦源中鎳鐵金屬元素已成為重要課題。本研究方法使用紅土鎳礦生料及煅燒後原料，以石墨為還原劑製成含碳球團，分別利用碳熱還原與熔分方式製備鎳鐵預還原團塊與鎳生鐵(鎳鐵合金)，找尋較佳鎳鐵品位和鎳回收率之較適操作條件(溫度、時間、C/O莫耳比等)。主要研究子題分別包括煅燒前處理、碳熱還原及高溫熔分等三個階段，依序求得較適合煅燒溫度、預還原球團優化條件、工業級規格鎳生鐵之優化富集條件。研究結果摘要如下:
(1)煅燒前處理: 當還原條件為1100oC持溫30分鐘及C/O=1，未煅燒紅土鎳礦含碳球團碳熱還原之鎳品位為4.7%，鎳回收率為84%；煅燒後(煅燒溫度900oC)紅土鎳礦含碳球團碳熱還原之鎳品位為11%，鎳回收率為57%。煅燒後紅土鎳礦含碳球團於還原溫度(1100oC)所得球團結構較為鬆散，有利於氣相還原，但不利於傳熱，由於鎳比鐵較易還原，故造成整體鎳品位上升，鎳回收率下降。
(2)預還原球團優化條件: 煅燒溫度400 oC之紅土鎳礦顆粒擁有較高的比表面積48.84 m2/g及平均孔洞尺寸29.68 Å，利於氣固還原反應。於還原溫度1100 oC、還原時間30分鐘及碳氧比0.6條件下，其預還原球團鎳品位及鎳回收率分別為最佳的78.2 wt%及90.2wt%。
(3)工業級規格鎳生鐵之優化富集條件: 煅燒溫度400oC之褐鐵型紅土鎳礦(貧鎳型)添加石墨之含碳球團，經碳熱還原與熔分後，所得最佳參數組合為：碳氧比為0.35、添加劑(SiO2)10%、還原溫度1100oC、還原時間30分鐘、熔分溫度1550oC及熔分時間為60分鐘。試驗所得鎳鐵合金之鎳品位16.8%及鎳回收率86.5%。(褐鐵型紅土鎳礦初始鎳品位1.18%)。
本研究亦利用生質煤(C/O=0.3)做為還原劑，添加於煅燒溫度400oC之褐鐵型紅土鎳礦，其含碳球團於預還原條件(還原溫度1100oC及還原時間30分鐘)和熔分條件(熔分溫度1550oC及熔分時間60分鐘)，實驗可得鎳鐵合金之鎳品位16.7%及鎳回收率87.7%。(褐鐵型紅土鎳礦初始鎳品位1.18%)。此外，延伸此研究方法應用至腐植型紅土鎳礦(富鎳型)，結果顯示，經400oC煅燒溫度處理後，於預還原條件(還原溫度1100oC及還原時間30分鐘)與熔分條件(熔分溫度1550oC及熔分時間60分鐘)下，可得鎳品位25.2%及鎳回收率81.2%之鎳鐵合金。(腐植型紅土鎳礦初始鎳品位3.10%)
綜合上述，本研究已建立一提煉紅土鎳礦之富集鎳研究方法，可應用於任何型態之紅土鎳礦，找尋較佳鎳生鐵鎳品位與鎳回收率之製程操作條件。利用低品級之褐鐵型紅土鎳礦於火法製程(煅燒前處理及還原熔分)冶煉出與富礦相同的成果並符合工業化標準(鎳品位15%及鎳回收率85%)的鎳生鐵產品並成為鎳的來源。

This research is divided into three parts, which include in calcination process, calcining temperatures and high temperature melting for limonite laterite. First, compared with reduced uncalcined laterite, when calcined limonite pellets were reduced at 1100oC for 30 min and carbon-oxygen ratio=1, the Nickel grade increased from 4.7% to 11.4% and the recovery of Nickel decreased from 84.5% to 57.1%. Second, 400oC-calcined limonite ore possesses a higher specific surface area of 48.84m2/g, and an average pore size of 29.68 Å, which provide better activity for reduction. And 400oC-calcined limonite ore obtained the best nickel grade of 78.2 % and the best recovery rate of 90.2 % under a reduction temperature of 1100oC, a reduction time of 30 min and a carbon-oxygen ratio of 0.6. Finally, 400oC-calcining limonite added graphite (C/O=0.35) and SiO2 (10%) which can obtain nickel grade 16.8% and nickel recovery 86.5% under a reduction temperature of 1100oC for a reduction time of 30 min and a melting temperature of 1550oC for a reduction time of 60 min. And also 400oC-calcining limonite added bio-coal (C/O=0.3) which can obtain nickel grade 16.7% and nickel recovery 87.7% under a reduction temperature of 1100oC for a reduction time of 30 min and a melting temperature of 1550oC for a reduction time of 60 min.

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