Application of a Complex Si-Al-Fe Reducing Agent for the Production of a Nickel-Containing Alloy

Application of a Complex Si-Al-Fe Reducing Agent for the Production of a Nickel-Containing Alloy | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article Application of a Complex Si-Al-Fe Reducing Agent for the Production of a Nickel-Containing Alloy Dauren Yessengaliyev, Bauyrzhan Kelamanov, Oleg Zayakin, Otegen Sariyev, and 7 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8646232/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 24 Mar, 2026 Read the published version in Scientific Reports → Version 1 posted 10 You are reading this latest preprint version Abstract To address the significant environmental challenges and technological limitations of conventional carbothermic ferronickel production, this study presents and optimizes an innovative metallothermic smelting process employing a complex silicon-aluminum-iron reducing agent (ferrosilicoaluminum, FeSiAl). For the first time, a comprehensive methodology integrating thermodynamic analysis, kinetic modeling, experimental design, and pilot-scale validation smelting has been applied to optimize the production of a nickel-containing alloy from lateritic ores of the Batamsha deposit (Kazakhstan). Thermodynamic modeling (HSC Chemistry) demonstrated that the combined use of Si and Al creates more favorable conditions for NiO reduction compared with their separate application, as evidenced by more negative ΔG values and higher equilibrium constants over the investigated temperature range (100–1600°C). Kinetic analysis based on non-isothermal thermogravimetric and differential thermal analysis (TG-DTA) revealed a pronounced synergistic effect: the FeSiAl system exhibits the lowest apparent activation energy (16.15 kJ mol - 1 ), which is 57% and 68% lower than those for ferrosilicon and aluminum-containing slag, respectively. This indicates a substantially enhanced reducibility and lower kinetic limitations. Process optimization was achieved through thermodynamic modeling in FactSage combined with a second-order rotatable central composite design (CCD). This approach enabled the development of predictive response surface models and the determination of optimal process parameters: smelting temperature of 1300–1350°C, FeSiAl addition of 10 wt.%, and lime flux addition of 38–40 wt.%. Validation smelting experiments conducted in a laboratory ore-thermal electric furnace confirmed the accuracy of the model, yielding 9.5 kg of a multicomponent alloy with the following composition (wt.%): Fe 70.0, Ni 8.0, Si 17.0, Cr 3.5, and Al 0.8. The accompanying slag exhibited a technologically favorable composition (wt.%): SiO 2 48.6, CaO 36.4, Al 2 O 3 10.2, and MgO 4.5, with a very low residual nickel oxide content (NiO 0.1%), confirming the high reduction efficiency. The recovery rates of iron and chromium into the metallic phase were 71% and 83%, respectively. The resulting Fe-Ni-Si-Cr-Al alloy is proposed as a potential master alloy for steelmaking or as a reducing agent in metallurgical processes. The developed FeSiAl-based metallothermic process represents an energy-efficient and environmentally more sustainable alternative to conventional carbothermic technology. Physical sciences/Chemistry Physical sciences/Engineering Earth and environmental sciences/Environmental sciences Physical sciences/Materials science lateritic nickel ore metallothermy ferrosilicoaluminum ferrosilicon aluminum slag thermodynamic modeling rotatable central composite design nickel-containing alloy Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Published Journal Publication published 24 Mar, 2026 Read the published version in Scientific Reports → Version 1 posted Editorial decision: Revision requested 03 Mar, 2026 Reviews received at journal 18 Feb, 2026 Reviewers agreed at journal 15 Feb, 2026 Reviews received at journal 12 Feb, 2026 Reviewers agreed at journal 10 Feb, 2026 Reviewers agreed at journal 03 Feb, 2026 Reviewers invited by journal 03 Feb, 2026 Editor assigned by journal 23 Jan, 2026 Submission checks completed at journal 23 Jan, 2026 First submitted to journal 20 Jan, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8646232","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":585010708,"identity":"6b7cc149-9f93-42fe-890d-71ab749c2df7","order_by":0,"name":"Dauren Yessengaliyev","email":"","orcid":"","institution":"K. 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For the first time, a comprehensive methodology integrating thermodynamic analysis, kinetic modeling, experimental design, and pilot-scale validation smelting has been applied to optimize the production of a nickel-containing alloy from lateritic ores of the Batamsha deposit (Kazakhstan). Thermodynamic modeling (HSC Chemistry) demonstrated that the combined use of Si and Al creates more favorable conditions for NiO reduction compared with their separate application, as evidenced by more negative ΔG values and higher equilibrium constants over the investigated temperature range (100\u0026ndash;1600\u0026deg;C). Kinetic analysis based on non-isothermal thermogravimetric and differential thermal analysis (TG-DTA) revealed a pronounced synergistic effect: the FeSiAl system exhibits the lowest apparent activation energy (16.15 kJ mol\u003csup\u003e-\u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e\u003c/sup\u003e), which is 57% and 68% lower than those for ferrosilicon and aluminum-containing slag, respectively. This indicates a substantially enhanced reducibility and lower kinetic limitations. Process optimization was achieved through thermodynamic modeling in FactSage combined with a second-order rotatable central composite design (CCD). This approach enabled the development of predictive response surface models and the determination of optimal process parameters: smelting temperature of 1300\u0026ndash;1350\u0026deg;C, FeSiAl addition of 10 wt.%, and lime flux addition of 38\u0026ndash;40 wt.%. Validation smelting experiments conducted in a laboratory ore-thermal electric furnace confirmed the accuracy of the model, yielding 9.5 kg of a multicomponent alloy with the following composition (wt.%): Fe 70.0, Ni 8.0, Si 17.0, Cr 3.5, and Al 0.8. The accompanying slag exhibited a technologically favorable composition (wt.%): SiO\u003csub\u003e2\u003c/sub\u003e 48.6, CaO 36.4, Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e 10.2, and MgO 4.5, with a very low residual nickel oxide content (NiO 0.1%), confirming the high reduction efficiency. The recovery rates of iron and chromium into the metallic phase were 71% and 83%, respectively. The resulting Fe-Ni-Si-Cr-Al alloy is proposed as a potential master alloy for steelmaking or as a reducing agent in metallurgical processes. The developed FeSiAl-based metallothermic process represents an energy-efficient and environmentally more sustainable alternative to conventional carbothermic technology.\u003c/p\u003e","manuscriptTitle":"Application of a Complex Si-Al-Fe Reducing Agent for the Production of a Nickel-Containing Alloy","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-02-05 12:04:13","doi":"10.21203/rs.3.rs-8646232/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Revision requested","date":"2026-03-04T03:55:19+00:00","index":"","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2026-02-18T10:48:19+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"321504820088334549594628003414101572946","date":"2026-02-15T10:48:19+00:00","index":"hide","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2026-02-12T07:03:31+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"64074637615139719807237055071438918055","date":"2026-02-10T12:24:56+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"255050935449740147229416553700976583750","date":"2026-02-03T11:29:59+00:00","index":"hide","fulltext":""},{"type":"reviewersInvited","content":"","date":"2026-02-03T10:45:57+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2026-01-24T02:01:00+00:00","index":"","fulltext":""},{"type":"checksComplete","content":"","date":"2026-01-24T02:00:19+00:00","index":"","fulltext":""},{"type":"submitted","content":"Scientific Reports","date":"2026-01-20T07:04:50+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"scientific-reports","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"scirep","sideBox":"Learn more about [Scientific Reports](http://www.nature.com/srep/)","snPcode":"","submissionUrl":"","title":"Scientific Reports","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Scientific Reports","inReviewEnabled":true,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"8cca16d3-455c-43d9-a187-d7fca006e3da","owner":[],"postedDate":"February 5th, 2026","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[{"id":62236135,"name":"Physical sciences/Chemistry"},{"id":62236136,"name":"Physical sciences/Engineering"},{"id":62236137,"name":"Earth and environmental sciences/Environmental sciences"},{"id":62236138,"name":"Physical sciences/Materials science"}],"tags":[],"updatedAt":"2026-03-30T16:26:18+00:00","versionOfRecord":{"articleIdentity":"rs-8646232","link":"https://doi.org/10.1038/s41598-026-45605-y","journal":{"identity":"scientific-reports","isVorOnly":false,"title":"Scientific Reports"},"publishedOn":"2026-03-24 16:12:06","publishedOnDateReadable":"March 24th, 2026"},"versionCreatedAt":"2026-02-05 12:04:13","video":"","vorDoi":"10.1038/s41598-026-45605-y","vorDoiUrl":"https://doi.org/10.1038/s41598-026-45605-y","workflowStages":[]},"version":"v1","identity":"rs-8646232","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8646232","identity":"rs-8646232","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}