Comparative Review of Processing Technologies for Oxidized (Lateritic) Nickel Ores

Processing of nickel ores is a key aspect of modern metallurgy due to the growing demand for nickel in stainless steel, battery production, and advanced materials. The depletion of high-grade sulfide ores has shifted attention toward oxidized (lateritic) nickel ores, which are characterized by complex mineralogy and low metal content. This study presents a comparative review of major processing technologies, including pyrometallurgical, hydrometallurgical, and hybrid approaches, with particular emphasis on their applicability to Kazakhstan’s limonitic laterites with high iron and low nickel content. The analysis shows that the most suitable processing routes for such ores include atmospheric acid leaching (AL), high-pressure acid leaching (HPAL), metallothermic reduction, and combined flowsheets integrating thermal and leaching stages. Among these, AL and hybrid approaches are identified as the most promising under resource-constrained conditions. Despite recent technological progress, challenges remain related to energy consumption, economic feasibility, and environmental impact. The study highlights the importance of developing energy-efficient and low-carbon technologies, including hydrogen-based reduction, and provides practical recommendations for selecting and adapting processing methods for Kazakhstan.