BIJIH BESI & AGLOMERISASI
Prof. Dr.-Ing. Bambang Suharno
Metallurgy and Materials Engineering Department
University of Indonesia
2010
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
University of Indonesia
Jenis Bijih Besi (Iron Ore)
Jenis oksida (terbanyak)
(
Fe O
= Magnetit
Fe
≈
72 4 %
(
Fe
3O
4= Magnetit
Fe
≈
72,4 %
Fe
2O
3= Hematit
Fe
≈
70 %
Jenis Hidroksida
Fe ≈
50 % ‐ 55 %
Fe
2O
3.nH
2O
= Hydrohematite/Laterit
Fe
2O
3*H
2O
= Goethit
Fe
2O
3*3 H
2O = Limonit
Jenis karbonat
FeCO
Siderit
Fe
≈
48 2 %
Metallurgy and Materials Engineering Department UI
FeCO
3= Siderit
Fe
≈
48,2 %
Jenis Titanious Ferrous
FeO.TiO
2= Pasir Besi/Ilmenit
Fe
≈
36,8 %, Ti
≈
5‐13 %
Jenis Sulfit
(
FeS
2= Sulfit
Fe
≈
46,7 %
University of Indonesia
Jenis Bijih Besi
Goethite
Limonite
Magnetite
University of Indonesia
Karakteristik Mineral Iron Ores
Metallurgy and Materials Engineering Department UI
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Chemicals composition of iron ores
from various countries (wt %)
University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Iron ore production
million metric tons
(2004)
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
University of Indonesia
Jenis Deposit Bijih Besi
Sumber Daya Terukur
11
Deposit Bijih Besi Indonesia
Besi
Ton Lokasi
Methasomatic Ore 320.462.611 Lampung, 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
University of Indonesia
Sebaran Batu Bara Lokal
Metallurgy and Materials Engineering Department UI
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)
University of Indonesia
800
PENINGKATAN NILAI JUAL MULAI BAHAN BAKU SAMPAI PRODUK JADI PADA INDUSTRI BESI BAJA
200 300 400 500 600 700 $ / T O N
KONS
PELET
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 IndonesiaBijih besi
Fe tinggi
Fe rendah
Pemurnian
> 6 mm
konsentrat ( 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
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)
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Gravimetry (Classifier)
Magnetic separator
Flotation
Iron ore yang sudah dimurnikan disebut
“KONSENTRAT”
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Crushing dan Screening
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Milling dan Spiral Classifier
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Magnetic Separator Process
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Bahan Baku Pasir Besi (Raw
Material)
• Sumber bahan baku Cipatujah, Tasikmalaya berada di
lokasi: Cidadap, Ciheras, Cimanuk, Cikaung Gading.
p
g
g
Ciheras
Cidadap
•
Kandungan
•
Fe = 35-40%
•
TiO2 = 5 – 15%
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Cikaung Gading
Cimanuk
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Konsentrat Pasir Besi (Ore
Treatment)
Pasir Besi
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Magnetic Separator
Konsentrat
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Spiral
Classifier
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Iron Ore Dressing
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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)
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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
University of Indonesia
Mining & Processing Operations
of Latheritic Ore in Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
University of Indonesia
Metallurgy and Materials Engineering Department UI
BIJIH BESI KARUNGAN
University of Indonesia
Metallurgy and Materials Engineering Department UI
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Pengolahan Bijih Besi
Sinter
Iron ore
Lump ore
Pellet
Blast F’ce
Foundry
Pig Iron
Fe tinggiUkuran halus Fe rendah
Metallurgy and Materials Engineering Department UI
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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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
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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
University of Indonesia
Proses Pembuatan Pellet
Dikembangkan dalam rangka pemanfaatan bijih besi
yang halus
yang 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 feed
Bentonit
:
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
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
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
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Traveling gate / conveyor belt
University of Indonesia
Campuran Sinter
Iron bearing fines ( 560% 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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Sinter Machine
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Proses Sinter
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Produk Sinter
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Requirements on physical and
metallurgical properties of sinter
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Operation Data of Sinter Plant in
Germany
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European
sinter plants
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Mesin Sinter di China
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Annular Sinter Maschine
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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
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dihisap
Terbentuk sinter pemecah ukuran 6 – 25 mm (didinginkan)
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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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Material Batu Besi yang diangkut dari lokasi
penambangan
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Mesin penghancur Bijih Besi
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Mesin Crushing/ Ball Mill
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Mesin Penghancur Bijih Besi
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Mesin Pencampur
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Mesin Pelletasi
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Dapur pembakaran pellet mentah
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Generator Listrik
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Iron Ore
Low Grade High Grade
Beneficiation
SOLUSI TEKNOLOGI PENGOLAHAN BIJIH BESI LOKAL
Size: 0.08-0.17mm
Screen
Rute proses PIBB
Crushing Crushing Concentrate (Fe>65%) Grinding Binder Pelletizer Pellet Coal Grate-Rotary Kiln
Indurator Natural Gas
Lump 6-25mm Screen Coke Sintering <6mm Binder Mixer
Metallurgy and Materials Engineering Department UI
Rotary Kiln Coal Fasmet, ITMK3,Inmetco, Comet Direct Reduction Blast Furnace
Coal Base Gas Base
Pelletizer