BigPatents India

The present invention relates to a process for preparation ferronickel from spent nickel catalyst. This invention particularly relates to a process for recovery of nickel as ferronickel from spent nickel catalyst by electrothermic smelting route. The present invention provides a process preparation of ferronickel from spent nickel catalyst which comprises. (a) mixing carbon powder and lime with ground spent nickel catalyst. (b) Adding water in the above mixture and making pallets of 5-20 mm size. (c) Allowing the said pallets to dry in the range of 110-1200C for a period of 12-24 h to remove moisture completely, (d) Melting the iron scrap or ferronickel by known process to make a pool for proper conduction, (e) Charging the dried pallets as obtained in step(iii) by adding this slowly into the above said iron scrap or ferronickel melt for complete smelting to obtain the iron to nickel ratio in the range of 8:2 to 1:9 and (f) Cooling and separating the metal and slag by the known process.