Ferro-Nickel (FeNi)
Ferro-Nickel (FeNi) is a master alloy of Iron (Fe) and Nickel (Ni), typically containing 20% to 50% Nickel, with the most common grades in the 20% to 50% range. FeNi is a crucial, cost-effective intermediate product used as the primary source of Nickel in the production of austenitic stainless steels (like the 300 series) and other specialty nickel-containing alloys.
It is manufactured by smelting lateritic nickel ores, a process that makes it a more direct and economical raw material source than pure nickel metal for high-volume steel grades.
Main Function and Mechanism
Nickel is the fundamental element required to form the austenite crystal structure in stainless steel, which grants superior ductility and corrosion resistance.
| COMPONENT | CHEMICAL SYMBOL | PROPERTY HIGHLIGHT |
| Nickel | Ni | Austenite stabilizer; greatly enhances toughness, ductility, and corrosion resistance. |
| Iron | Fe | Carrier metal; forms the bulk of the alloy. |
| CLASSIFICATION | MELTING POINT | PRIMARY APPLICATION FOCUS |
| Alloying Metal | ~1430°C (2606 F) | Bulk production of Nickel-containing stainless steel and heat-resistant alloys. |
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Austenite Stability | EXTREME | Ni is the key element that stabilizes the face-centered cubic (FCC) austenite phase down to room temperature, ensuring non-magnetic and highly ductile steel. |
| Cost-Effectiveness | HIGH | Less expensive per unit of Ni than electrolytic pure nickel, making it ideal for bulk steel production. |
| Corrosion Resistance | IMPROVED | Enhances resistance to both general corrosion and stress-corrosion cracking. |
1. Austenitic Stainless Steel Production
The largest application for FeNi is in the 300 series stainless steels (e.g., 304, 316).
- Austenite Stabilization: Iron-Chromium alloys (stainless steel) are naturally ferritic (body-centered cubic, BCC). To create the desirable austenitic (face-centered cubic, FCC) structure—which is non-magnetic, highly ductile, and tough—a potent austenite stabilizer is required. Nickel is the premier element for this, with a typical Ni content of 8% to $14% needed in the final steel. FeNi provides this required Ni.
- Corrosion Improvement: Nickel enhances the stability of the passive chromium oxide film and improves resistance to chemical attack, especially acidic and chloride environments.
2. Other Nickel Alloys
FeNi is also used to supply nickel to various other nickel-containing steels, including:
- Low-Temperature Steels: Nickel enhances toughness and ductility at cryogenic temperatures.
- Structural and HSLA Steels: 6$\text{Ni}$ is used to improve the overall mechanical properties and fracture toughness.
Technical Guidance and Form
- Form: FeNi is typically supplied in pig or lump form. The high density of the alloy ensures excellent penetration through the slag layer and rapid, predictable dissolution into the molten steel bath.
- Purity: While generally clean, the minor elements and tramp metals present in FeNi (which vary depending on the nickel ore source, e.g., lateritic vs. sulfidic) must be considered for high-purity or specialty alloys, where purer electrolytic nickel may be required for the final trimming.
- Addition: FeNi is added early in the steelmaking process, typically charged into the Electric Arc Furnace (EAF) along with the scrap and other high-melting-point alloys to ensure complete dissolution.
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
