HOT METAL PRODUCTION HOT METAL PRODUCTION FROM A TITANIUM CONTAINING FROM A TITANIUM CONTAINING

IRON SANDIRON SAND

Adil Jamali, Eng., M.Sc.Adil Jamali, Eng., M.Sc.

WAITRO-CMRDI WORKSHOP ON NEW TRENDS IN MINERAL PROCESSING 22-25 JANUARY 2006, Cairo, Egypt. -

Introduction Introduction

Indonesian SteelIndonesian Steel

Production (2005)Production (2005) : 4.4 M.Ton : 4.4 M.Ton

Consumption (2004) : 22 kg/cap-yearConsumption (2004) : 22 kg/cap-year

Raw MaterialRaw Material

Hemato MagnetiteHemato Magnetite :small and :small andscattered 15 M.Tonscattered 15 M.Ton

Iron Sand containing TiOIron Sand containing TiO22 165 M.Ton 165 M.Ton

Lateritic Iron Ore 974 M.Ton Lateritic Iron Ore 974 M.Ton

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Iron Sand Raw Material Raw Material Conc.Conc.

FeFe 12.5 % 12.5 % 58 %58 %

MnOMnO22 0.6 %0.6 %

AlAl22OO33 7.6 % 7.6 % 3.6 %3.6 %

CaOCaO 13.2 % 13.2 % 1.5 %1.5 %

MgOMgO 7.7 % 7.7 % 2.4 %2.4 %

NaNa22OO 0.03 %0.03 %

KK22OO 0.18 %0.18 %

SiOSiO22 34.4 % 34.4 % 2.5 %2.5 %

TiOTiO22 1.9 % 1.9 % 8.5 %8.5 %

PP 0.3 % 0.3 % 0.13 %0.13 %

SS 0.04 % 0.04 % 0.06 %0.06 %BackBack

ProblemsProblems

How to produce iron from iron sandHow to produce iron from iron sand

TiOTiO22 : 7 – 12 %: 7 – 12 %

Vanadium Vanadium

Use the available technology / Use the available technology / equipment equipment

HYL – EAFHYL – EAF

Induction FurnaceInduction Furnace

Small – medium scaleSmall – medium scale

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Hot MetalHot Metal

ExperimentExperiment

SpongSpongee

Pellet Pellet CompositeComposite

PelletizerPelletizer

MixerMixer

Reduction Reduction in Shaft Kilnin Shaft Kiln

Melting Shaft Melting Shaft FurnaceFurnaceSlagSlag

Hot MetalHot Metal

SlagSlag

BentoniteBentoniteCoalCoal Iron SandIron Sand

Melting in InductionMelting in InductionFurnaceFurnace

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Separation of TiOSeparation of TiO22

TiOTiO22 SlagSlag

MMTT = 1400 = 1400 ˚̊CC

Slag composition adjustmentSlag composition adjustment

TiOTiO22 ::

SiOSiO22 ::

CaOCaO ::

to satisfy the TiOto satisfy the TiO22 – SiO – CaO liquid at – SiO – CaO liquid at

T = 1400 T = 1400 ˚̊C in the phase diagramC in the phase diagram

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TiOTiO22 – SiO – SiO22 – CaO Phase Diagram – CaO Phase Diagram

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Experiment Result (I)Experiment Result (I)I. Sponge iron from shaft furnaceI. Sponge iron from shaft furnace = 400 mm= 400 mm h = 1500 cmh = 1500 cm

Fe %Fe % Wt %Wt %Pellet spongePellet sponge : 80 % : 80 % 45 %45 %Fine SpongeFine Sponge : 86 % : 86 % 35 %35 %Sintered Sponge Sintered Sponge : 67 %: 67 % 20 %20 %

II. Slag can be tapped at T II. Slag can be tapped at T 1400 1400 ˚̊C C from shaft furnace and induction from shaft furnace and induction furnace furnace

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Experiment Result (II)Experiment Result (II)

III. Hot Metal composition III. Hot Metal composition from induction furnacefrom induction furnace

FeFe = 93.9 %= 93.9 %

SiSi = 1.81 %= 1.81 %

Mn Mn = 0.8 %= 0.8 %

PP = 0.027 %= 0.027 %

SS = 0.08 %= 0.08 %

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Why Induction Furnace ?Why Induction Furnace ?

FamiliarityFamiliarity

Lower power consumption Lower power consumption

Easy to adjust metal Easy to adjust metal composition composition

Small scale Small scale

End product from ore is End product from ore is possiblepossible

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ConclusionConclusion1.1. Hot metal can be produced from iron Hot metal can be produced from iron

sand containing sand containing 8 % Titanium Dioxide 8 % Titanium Dioxide by three processing steps :by three processing steps :

Production of composite pelletProduction of composite pelletReduction in shaft furnace Reduction in shaft furnace Melting in induction furnaceMelting in induction furnace

2.2. Titanium can be separated into slag that Titanium can be separated into slag that flow at flow at T = 1400 T = 1400 ˚̊CC

3.3. The prospect of producing “end product” The prospect of producing “end product” is now open directly from iron sand is now open directly from iron sand

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Thanks to :Thanks to :

WAITROWAITRO

CMRDICMRDI

Workshop ParticipantsWorkshop Participants

Organization Organization committeecommittee

HOT METAL PRODUCTION HOT METAL PRODUCTION FROM A TITANIUM CONTAINING FROM A TITANIUM CONTAINING

IRON SANDIRON SAND

• Introduction Introduction • Iron Sand

• ProblemsProblems

• ExperimentExperiment

• Separation of Separation of TiO2TiO2

• TiO2 – SiO2 – CaO TiO2 – SiO2 – CaO Phase Diagram Phase Diagram • Experiment Result Experiment Result (I)(I)• Experiment Result Experiment Result (II)(II)• Why Induction Furnace ?Why Induction Furnace ?• ConclusionConclusion

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