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BIJIH BESI & AGLOMERISASI
Prof. Dr.-Ing. Bambang Suharno
Metallurgy and Materials Engineering DepartmentUniversity of Indonesia2010
University of Indonesia
Bahan Baku Proses Pembuatan Besi Baja
Iron Ore
Reduktor Coke (Blast Furnace)
Coal (Reduksi Langsung dan Smelting Reduction)
Natural Gas (CH4) (Reduksi Langsung)
Metallurgy and Materials Engineering Department UI
Scrap
Additive (Flux): CaO
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University of Indonesia
Jenis Bijih Besi (Iron Ore)
Jenis oksida (terbanyak) (Fe O = Magnetit Fe ≈ 72 4 %(Fe3O4 = Magnetit Fe ≈ 72,4 %
Fe2O3 = Hematit Fe ≈ 70 %
Jenis Hidroksida Fe ≈ 50 % ‐ 55 %
Fe2O3.nH2O = Hydrohematite/Laterit
Fe2O3*H2O = Goethit
Fe2O3*3 H2O = Limonit
Jenis karbonatFeCO Siderit Fe ≈ 48 2 %
Metallurgy and Materials Engineering Department UI
FeCO3 = Siderit Fe ≈ 48,2 %
Jenis Titanious Ferrous FeO.TiO2 = Pasir Besi/Ilmenit Fe ≈ 36,8 %, Ti ≈ 5‐13 %
Jenis Sulfit (FeS2 = Sulfit Fe ≈ 46,7 %
University of Indonesia
Jenis Bijih Besi
Goethite Limonite Magnetite
Metallurgy and Materials Engineering Department UIHematite Hematite Hematite
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University of Indonesia
Karakteristik Mineral Iron Ores
Metallurgy and Materials Engineering Department UI
University of Indonesia
Chemicals composition of iron ores from various countries (wt %)
Metallurgy and Materials Engineering Department UI
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University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Iron ore production million metric tons (2004)
Metallurgy and Materials Engineering Department UI
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University of Indonesia
Persyaratan Bijih Besi
High Iron content
Minim m imp rities (S P As Zn Pb Na K ) Minimum impurities (S, P, As, Zn, Pb, Na, K,)
High content of basic oxides in gangue (self fluxing ore)
Minimum derivation in chemicals composition
High reducability
High strength
Metallurgy and Materials Engineering Department UI
g g
Minimum of fines and narrow size distribution (for a uniform gas flow)
University of Indonesia
Sebaran Bijih Besi Lokal
Metallurgy and Materials Engineering Department UI
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University of Indonesia
Jenis Deposit BijihBesi
Sumber Daya Terukur
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Deposit Bijih Besi Indonesia
BesiTon Lokasi
Methasomatic Ore 320.462.611Lampung, West of Sumatera, Belitung, west of Kalimantan, Tanalang, Plaihari, dll.
Lateritic 1 391 246 630 South of Kalimantan, Pomalaa,
Metallurgy and Materials Engineering Department UI
Lateritic 1.391.246.630 , ,Halmahera, dll.
Iron Sand 382.000.000 South of Java Island Coast, Sumbar, Bengkulu, NTB, Sulsel dll.
Sumber : Direktorat Mineral Batubara ESDM
University of Indonesia
Bijih Besi Sekitar Lampung
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University of Indonesia
Sebaran Batu Bara Lokal
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1.000 juta ton
3.000 juta ton
10.000 juta ton
20.000 juta ton “Batubara kualitas Bituminous banyak terdapat di Kalimantan Timur”
University of Indonesia
Deposit Batubara (sumber C atau CO sebagai zat pereduksi)
Metallurgy and Materials Engineering Department UI
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University of Indonesia
800
PENINGKATAN NILAI JUAL MULAI BAHAN BAKU SAMPAI PRODUK JADI PADA INDUSTRI BESI BAJA
200
300
400
500
600
700
$ /
TO
N
KONSPELET
PIG IRON
SLAB HRC
Metallurgy and Materials Engineering Department UI
0
100
1 2 3 4 5 6
ORE KONS
PT KRAKATAU STEEL
University of Indonesia
Bijih besi
Fe tinggi Fe rendah
Pemurnian
> 6 mmkonsentrat ( Fe tinggi )
ukuran rendah
Aglomerisasi (Pellet , Sinter)> 6 mm
< 6 mm
Lump ore
Metallurgy and Materials Engineering Department UI
Blast Furnace = Pig Iron (Hot Metal)
Reduksi Langsung = Sponge Iron
Ukuran 6 mm batas undersize yang masih dapat diolah
Umumnya berukuran 12 – 30 mm
Export
Pellet
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University of Indonesia
Proses pemurnian Bijih Besi
Meningkatkan kandungan Fe pada ‘low grade raw ore”
Memisahkan senyawa yang tidak diinginkan Penghalusan ukuran bijih besi (< 2 mm) untuk dapat
dibuat pellet Proses yang dilakukan antara lain: Washing of ore Crushing/ grinding Gravimetry (Classifier)
Metallurgy and Materials Engineering Department UI
Gravimetry (Classifier) Magnetic separator Flotation
Iron ore yang sudah dimurnikan disebut “KONSENTRAT”
University of Indonesia
Crushing dan Screening
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University of Indonesia
Milling dan Spiral Classifier
Metallurgy and Materials Engineering Department UI
University of Indonesia
Magnetic Separator Process
Metallurgy and Materials Engineering Department UI
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University of Indonesia
Bahan Baku Pasir Besi (Raw Material)
• Sumber bahan baku Cipatujah, Tasikmalaya berada dilokasi: Cidadap, Ciheras, Cimanuk, Cikaung Gading.p g g
CiherasCidadap
• Kandungan• Fe = 35-40%• TiO2 = 5 – 15%
Metallurgy and Materials Engineering Department UI
Cikaung GadingCimanuk
University of Indonesia
Konsentrat Pasir Besi (Ore Treatment)
Pasir Besi
Metallurgy and Materials Engineering Department UI
Magnetic Separator
Konsentrat
CMPFA Metalurgi UI
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University of Indonesia
Spiral Classifier
Metallurgy and Materials Engineering Department UI
University of Indonesia
Iron Ore Dressing
Metallurgy and Materials Engineering Department UI
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University of Indonesia
Pengolahan Latheritic Ore di Indonesia
Proses penambangan dan pemurnian dari bijih besi muda
(bijih besi laterit) di Indonesia telah dilakukan oleh 2 (dua)(bijih besi laterit) di Indonesia telah dilakukan oleh 2 (dua)
perusahaan, yaitu :
1. PT. KRAKATAU STEEL (Persero)
- Project began : Oktober 2006
- Kapasitas : 100 ton per hari
2 PT SILO (Sebuku Iron Lateritic Ores)
Metallurgy and Materials Engineering Department UI
2. PT. SILO (Sebuku Iron Lateritic Ores)
- Project began : 2000 (actual start-up 2003)
- Kapasitas : 2,000 – 2,500 ton per hari
University of Indonesia
Metallurgy and Materials Engineering Department UI
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University of Indonesia
Mining & Processing Operations of Latheritic Ore in Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UILATERITE IRON ORE
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University of Indonesia
Metallurgy and Materials Engineering Department UIBIJIH BESI KARUNGAN
University of Indonesia
Metallurgy and Materials Engineering Department UI
IRON ROCK
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University of Indonesia
Pengolahan Bijih Besi
Sinter
Iron ore Lump ore
Pellet
Blast F’ce Foundry
Pig Iron
Fe tinggi
Ukuran halus
Fe rendah
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Red Lgsng Steel Plant
Sponge Iron
First Step : Tentukan
Kualitas dan Kuantitas
Cadangan Bijih Besi
University of Indonesia
Tidak semua bijih besi memiliki kadar Fe tinggi untuk diolah di tanur tinggi atau tanur
Alasan Aglomerisasi
tinggi untuk diolah di tanur tinggi atau tanur lainnya
Ukuran yang seragam diperlukan agar : optimum rate of gas flow uniform gas flow , with a minimum of
channeling
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Ukuran partikel kecil , menyebabkan adanya sejumlah fine material yang keluar tanur dan masuk ke ‘gas recovery’ system
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University of Indonesia
Proses Aglomerisasi
Kriteria pemilihan ukuran partikel > 2 mm ukuran partikel > 2 mm
sinter
ukuran partikel < 0,2 mm pellet
Lokasi Pembuatan Sinter biasanya dekat TT
P ll t bi d k t
Metallurgy and Materials Engineering Department UI
Pellet biasanya dekat penambangan
University of Indonesia
Penggunaan Pellet dan Sinter
Europa Union : 65% sinter, 24% pellet, 13% llump ore
Brazil, Japan, Korea Selatan: > 70% sinter
Canada, USA: 91 dan 81% pellets
Penggunaan Lump ore pada blast furnace dibatasi tak lebih dari 10 – 15%
Metallurgy and Materials Engineering Department UI
Pada blast furnace sebetulnya memungkinkan untuk mengolah bijih besi dengan berbagai kadar Fe. Namun semakin tinggi kadar Fe akan semakin ekonomis
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University of Indonesia
Proses Pembuatan Pellet
Dikembangkan dalam rangka pemanfaatan bijih besi yang halusyang halus
Green pellet (pellet mentah)
Partikel bijih besi halus yang dicampur oleh air dan bentonit, digumpalkan melalui proses rotasi sehingga terjadi bola-bola aglomerat (kekuatan 20 – 50 N/ pellet)
Burn pellet (pellet bakar)
Metallurgy and Materials Engineering Department UI
bola-bola aglomerat dikeraskan dengan cara dibakar pada: conveyor belt, grate kiln atau shaft furnace
(kekuatan hingga 2500 N/ pellet)
University of Indonesia
Pellet Mentah (Green Pellet)
Bijih besi halus dengan campuran
Bentonit : 8 3 - 10 kg/ ton of feedBentonit : 8,3 10 kg/ ton of feed% air : (4-7%)
β
ukuran pellet : ± 8 – 30 mm
biasanya 10 – 15 mm
Metallurgy and Materials Engineering Department UI
Kekuatan Green pellet :
20 – 50 N / pellet
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University of Indonesia
Pelletasi
Faktor penentu kadar air harus optimal
jika kekuatan green pellet rendah dibakar (T = 1000 oC)
kehalusan partikel
penambahan bentonit
kadar bahan sampingan
diameter , kecepatan piringan
Metallurgy and Materials Engineering Department UI
agar kekuatan : 2500 N/pellet
Alat : Shaft furnace
Grate kiln
Traveling gate / conveyor belt
University of Indonesia
Proses Pelletasi
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University of Indonesia
Parameters of the discs for production of green pellet
Metallurgy and Materials Engineering Department UI
University of Indonesia
Pellet Bakar (Burn Pellet)
Dibakar 1000 OC, kekuatan : 2500 N/pellet
T li t / b lt
Grate Kiln
Metallurgy and Materials Engineering Department UI
Traveling gate / conveyor belt
Shaft Furnace
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University of Indonesia
Campuran Sinter
Iron bearing fines ( 50-60% of raw mix, grain sixe 0-10 mm, incl. 70%> 0,2mm)10 mm, incl. 70% 0,2mm)
Solid fuel (3-4% coke breeze 0-3mm)
Flux (10-15%, grain size <3mm, limestone, lime, dolomite)
Circulating materials (4.5 – 5%, mill scale, BF and BOF dusts)
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Return sinter fines (25-35%, grain size < 6.3 mm)
Moisture (water 5-9%)
University of Indonesia
Proses Sinter
Dalam proses ini bijih besi < 5 mm dicampur dengan
cokes breeze : 8 % (bahan bakar)( )
air : 5-9 % (kemampuan ikat Fe tinggi)
Bahan sirkulasi : 25 – 35 %
Additiv : 10-15 % (CaO , Dolomit)
Metallurgy and Materials Engineering Department UI
Dicampur (mixing drum)
Sinter machine
( lebar : ± 4 m ) kecepatan : 5 – 9 m/menit (panjang : ± 100 m)
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University of Indonesia
Sinter Machine
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University of Indonesia
Proses Sinter
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University of Indonesia
Produk Sinter
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University of Indonesia
Requirements on physical and metallurgical properties of sinter
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University of Indonesia
Operation Data of Sinter Plant in Germany
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University of Indonesia
European sinter plants
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Mesin Sinter di China
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University of Indonesia
Annular Sinter Maschine
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University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Proses Sinter
Umpan sinter diletakkan dalam alat panggang & dibakar
permukaannya (1300 – 1480 oC)
Setelah terbakar udara panas dihisap dari atas ke bawah
zona pembakaran bergerak dari atas ke bawah
h = 40-45 cm
Metallurgy and Materials Engineering Department UI
dihisap Terbentuk sinter pemecah ukuran 6 – 25 mm (didinginkan)
< 6 mm disirkulasikan
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University of Indonesia
Proses Sinter
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Lay Out Sinter Plant
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Sinter capacities (million t/a)
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Material Batu Besi daerah Garut
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University of Indonesia
Material Batu Besi yang diangkut dari lokasi penambangan
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University of Indonesia
Mesin penghancur Bijih Besi
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Mesin Crushing/ Ball Mill
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University of Indonesia
Mesin Penghancur Bijih Besi
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University of Indonesia
Mesin Pencampur
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University of Indonesia
Mesin Pelletasi
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University of Indonesia
Dapur pembakaran pellet mentah
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University of Indonesia
Generator Listrik
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University of Indonesia
Iron Ore
Low Grade High Grade
Beneficiation
SOLUSI TEKNOLOGI PENGOLAHAN BIJIH BESI LOKAL
Size: 0.08-0.17mm
Screen
Rute proses PIBBCrushing Crushing
Concentrate (Fe>65%)
Grinding
Binder
PelletizerPellet
Coal
Grate-Rotary Kiln Indurator
Natural Gas
Lump 6-25mm
Screen
Coke
Sintering
<6mm
BinderMixer
Metallurgy and Materials Engineering Department UI
Rotary Kiln
Coal
Fasmet, ITMK3,Inmetco,
Comet
Direct Reduction
Blast Furnace
Coal Base Gas Base
Pelletizer
DRI DRI DRIPig Iron