New Model to Predict Nickel Extraction from Lateritic Ores During the Roasting–Reduction of the Caron Process

Determining nickel extraction during the roasting–reduction stage of the Caron process is an essential tool for controlling the metallurgical efficiency of the technology. This study evaluated the performance of a new semi-empirical kinetic model for predicting nickel extraction during the reduction of lateritic ores predominantly composed of iron oxides and oxyhydroxides in multiple-hearth furnaces. To achieve this, the lateritic ore was characterised by scanning electron microscopy (SEM) before and after the reduction process. The temperature in hearth six was varied between 495 and 780 °C by adjusting the post-combustion air supply. The proposed model demonstrated high predictive accuracy for nickel extraction, with absolute and residual errors below 1.70% and 1.15%, respectively. The findings emphasise the importance of controlling metallurgical efficiency through mathematical models that incorporate key technological variables and the kinetic behaviour of the process.