Nickel losses in the slag generated at Larco electric reduction furnac
es (ERF) during smelting of Greek laterites account for about 20% of t
he total nickel of the feed. The recovery of the nickel contained in t
he slag as well as in its magnetic concentrate was studied under diffe
rent methods. The experimental results have shown that a nickel recove
ry in the range of 75-90% is possible by allowing the slag to settle.
Washing by low carbon steel can be performed during the final stages o
f the settling process as it improves the finally attained nickel reco
very up to 94.4%. The simultaneous carbon reduction and settling proce
ss do not favour the Ni- recovery as the produced carbon monoxide and
dioxide cause boiling of the bath which promotes the flotation of the
metallic grains. In all cases a reoxidation of nickel was observed aft
er 20min approximately. Settling of the ferronickel grains was describ
ed by a mathematical model. The model's results are in good agreement
to the experimental ones for the initial 20min of the process. A modif
ied model was elaborated combining the settling of the metallic grains
with the nickel reoxidation reaction. This model describes with adequ
ate accuracy the whole Ni- recovery process. The developed model can b
e proven helpful in the design of a slag cleaning step for metal recov
ery utilizing a slag settling furnace operating on line to the ERF.