Physical Simulation of Recovering Cast iron from Bayer Red Mud

Abstract

The physical simulation of a pyrometallurgical process was conducted through a small electric arc furnace. Grey cast iron has been recovered by carbothermic reduction process by adding a certain amount of laterite nickel ore to Bayer red mud. In addition to Fe and Ni, Ti and Cr could be also extracted and entered into the melt. It was discovered that the cast iron without Ni was white cast iron, that is, element C was present as the cementite which was a super hard compound. With the increasing of Ni content up to 0.6%, the "white" microstructure was gradually transferred to "grey". The element C was present as free graphite. Compared with traditional grey cast iron, the RM grey cast iron provides better strength and corrosion resistance.