Towards a low-carbon future: Reassessing hydrogen plasma smelting reduction technology for sustainable ferronickel production

Authors

  • Izzul Islam Metallurgical Engineering Department, Institut Teknologi Bandung, Bandung 40132, Indonesia , Bandung Institute of Technology image/svg+xml , Metallurgical and Materials Engineering Department, Hasanuddin University, Gowa 92171, Indonesia , Hasanuddin University image/svg+xml https://orcid.org/0009-0005-3232-4522
  • Dale Tandersen Metallurgical Engineering Department, Institut Teknologi Bandung, Bandung 40132, Indonesia , Bandung Institute of Technology image/svg+xml https://orcid.org/0009-0007-7553-7936
  • Abrar Taimullah Metallurgical Engineering Department, Institut Teknologi Bandung, Bandung 40132, Indonesia , Bandung Institute of Technology image/svg+xml
  • Yuli Andi Sata Research and Development Department, PT. Antam Tbk, Jakarta 12530, Indonesia
  • Yopi Hendrawan Metallurgical Engineering Department, Institut Teknologi Bandung, Bandung 40132, Indonesia , Bandung Institute of Technology image/svg+xml
  • Taufiq Hidayat Metallurgical Engineering Department, Institut Teknologi Bandung, Bandung 40132, Indonesia , Bandung Institute of Technology image/svg+xml
  • Zulfiadi Zulhan Metallurgical Engineering Department, Institut Teknologi Bandung, Bandung 40132, Indonesia , Bandung Institute of Technology image/svg+xml

DOI:

https://doi.org/10.15282/jmes.20.3.2026.2.0879

Keywords:

HPSR, Ferronickel, Hydrogen Plasma, Thermodynamics, Metal recovery, Laterite nickel ore

Abstract

More than 95% of global ferronickel production is currently dominated by the Rotary Kiln-Electric Furnace (RKEF) process, which significantly contributes to Greenhouse Gas (GHG) emissions due to its reliance on fossil-based carbon reductants. The use of hydrogen as a sustainable and green reductant presents a promising pathway for mitigating these emissions. This study aimed to reassess hydrogen plasma smelting reduction (HPSR) at the lowest investigated total gas flow by linking hydrogen supply to stoichiometric demand and evaluating alloy quality and Fe–Ni recovery. Saprolitic nickel ore was characterized, calcined at 900 °C for 3 h, formed into a 3 g briquette, assessed using FactSage 8.2, and treated for 180 s at a total H2–Ar flow of 2 L/min and H2:Ar = 4:1; the products were examined using SEM-EDS and elemental mapping. The 2 L/min total flow comprised 1.6 L/min H2 and 0.4 L/min Ar and supplied 4.8 L H2, approximately 20 times the calculated stoichiometric requirement. The resulting alloy comprised 72.35% iron (Fe) and 24.82% nickel (Ni). The estimated recoveries of Fe and Ni were 61.09% and 94.39%, respectively, and the measured alloy composition differed from the equilibrium prediction by 2.04 percentage points for Fe and 0.52 percentage points for Ni. These results show that the 2 L/min condition provides sufficient stoichiometric excess to produce well-separated ferronickel within 180 s at the lowest gas throughput evaluated.

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Published

2026-09-30

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Volume 20 No. 3 (September 2026)

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How to Cite

[1]
I. Islam, “Towards a low-carbon future: Reassessing hydrogen plasma smelting reduction technology for sustainable ferronickel production”, J. Mech. Eng. Sci., vol. 20, no. 3, p. In-Press, Sep. 2026, doi: 10.15282/jmes.20.3.2026.2.0879.