In the conventional process to produce ferronickel, the drying and calcining of ore is followed by smelting in either three- or six-electrode AC arc furnaces. DC arc furnace technology has been shown to have advantages over traditional AC techniques in several applications, mainly because it can process fines efficiently. Laterite Ni ores contain a large proportion of fines and require agglomeration to reduce losses during pre-treatment and smelting. DC arc furnace technology allows pyrometallurgical processing of fine ores and metals without prior agglomeration. In addition, the preheating and/or prereduction of fine materials in a fluidized-bed reactor as a mechanism for saving electrical energy is a very cost-effective method of reducing operating costs with only a small capital expenditure addition. Mintek has carried out research into the smelting of ferronickel using a DC arc furnace and has developed the technology for scaling the pilot plant work to commercial size. Coal- and gas-based Mintek ferronickel production processes are outlined schematically. Work could lead to establishing a ferronickel plant in South Africa in conjunction with a stainless steel mill.