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PROSES Pengolahan bijih besi
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1
Metallurgy and Materials Engineering DepartmentUniversity of Indonesia2008
BIJIH BESI & AGLOMERISASI
Dr.-Ing. Bambang Suharno
University of Indonesia
Metallurgy and Materials Engineering Department UI
Jenis Bijih Besi
Jenis oksida (terbanyak) Magnetit (Fe3O4) Fe ≈ 60 – 70 %Hematit (Fe2O3) Fe ≈ 55 – 60 %
Jenis HidroksidaHematit yang teroksidasi oleh air
Fe2O3.x H2O = LateritFe2O3. H2O = GoethitFe2O3.3 H2O = Limonit
Jenis karbonatFeCO3 = Siderit
FeCO3 Fe2O3 + CO2
Jenis Titanious Ferrous (FeO.TiO2) = Pasir Besi
kadar Fe rendahFe = 20 – 50 %
Fe ≈ 30 – 40 %
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Jenis Bijih Besi
Goethite Limonite Magnetite
Hematite Hematite Hematite
University of Indonesia
Metallurgy and Materials Engineering Department UI
Bijih Besi di Indonesia
Bijih besi di Indonesia
Kualitas
Kuantitas
Jenis Hematit / Magnetit
Gunung Talang (Kal-Sel) .. juta ton
Sumatra / Flores …. juta ton
Pulau Sebuku, Kal-Bar ???
Jenis Titani FerrousPantai selatan Jawa (Jogja) 230 juta ton Fe ≈ 12-30 %
Raw material semen
Prospek ada/ Masih dalampenyelidikan
50 – 70 % Fe
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Bijih Besi Sekitar Lampung
University of Indonesia
Metallurgy and Materials Engineering Department UI
Bijih besi
Fe tinggi
> 6 mm
Blast Furnace = Pig Iron (Hot Metal)
Reduksi Langsung = Sponge Iron
Fe rendah
Pemurnian
konsentrat ( Fe tinggi )ukuran rendah
Aglomerisasi (Pellet , Sinter)> 6 mm
< 6 mm
Ukuran 6 mm batas undersize yang masih dapat diolahUmumnya berukuran 12 – 30 mm
Export
Lump ore
Pellet
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses pemurnian Bijih Besi
Meningkatkan kandungan Fe pada ‘low grade raw ore”Memisahkan senyawa yang tidak diinginkanPenghalusan ukuran bijih besi (< 2 mm) untuk dapatdibuat pelletProses yang dilakukan antara lain:
Washing of ore 1 6 yCrushing/ grinding 2 7Gravimetry (Classifier) 3 8Magnetic separator 4 9Flotation 5 x
TUGAS BUAT DETAIL PROSES TERSEBUT
University of Indonesia
Metallurgy and Materials Engineering Department UI
Crushing dan Screening
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Milling dan Spiral Classifier
University of Indonesia
Metallurgy and Materials Engineering Department UI
Magnetic Separator Process
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Spiral Classifier
University of Indonesia
Metallurgy and Materials Engineering Department UI
Iron Ore Dressing
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Pengolahan Latheritic Ore di Indonesia
Proses penambangan dan pemurnian dari bijih besi muda(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) - 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
Metallurgy and Materials Engineering Department UI
Mining & Processing Operations of Latheritic Ore in Indonesia
University of Indonesia
Metallurgy and Materials Engineering Department UI
Pengolahan Bijih Besi
Iron ore Lump ore
Pellet
Blast F’ce
Red Lgsng
Foundry
Steel Plant
Sponge Iron
Pig Iron
Fe tinggi
Ukuran halus
Fe rendah
First Step : Tentukan
Kualitas dan Kuantitas
Cadangan Bijih Besi
Sinter
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Tidak semua bijih besi memiliki kadar Fe tinggi untuk diolah di tanur tinggi atau tanurlainnyaUkuran yang seragam diperlukan agar :
optimum rate of gas flowuniform gas flow , with a minimum of channelingUkuran partikel kecil , menyebabkan adanyasejumlah fine material yang keluar tanur danmasuk ke ‘gas recovery’ system
Alasan Aglomerisasi
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Aglomerisasi
Kriteria pemilihanukuran partikel > 2 mm sinterukuran partikel < 0,2 mm pellet
Lokasi PembuatanSinter biasanya dekat TTPellet biasanya dekatpenambangan
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Pembuatan Pellet
Dikembangkan dalam rangka pemanfaatan bijih besiyang halus
Green pellet (pellet mentah)Partikel bijih besi halus yang dicampur oleh air danbentonit, digumpalkan melalui proses rotasi sehinggaterjadi bola-bola aglomerat (kekuatan 20 – 50 N/ pellet)
Burn pellet (pellet bakar)bola-bola aglomerat dikeraskan dengan cara dibakarpada: conveyor belt, grate kiln atau shaft furnace(kekuatan hingga 2500 N/ pellet)
University of Indonesia
Metallurgy and Materials Engineering Department UI
Pellet Mentah (Green Pellet)
Bijih besi halus dengan campuran
Bentonit : 8,3 - 10 kg/ ton of feed% air : (4-7%)
β
ukuran pellet : ± 8 – 30 mm
biasanya 10 – 15 mm
Kekuatan Green pellet :
20 – 50 N / pellet
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Pelletasi
jika kekuatan green pellet rendah dibakar (T = 1000 oC)
agar kekuatan : 2500 N/pellet
Alat : Shaft furnaceGrate kilnTraveling gate / conveyor belt
Faktor penentukadar air harus optimalkehalusan partikelpenambahan bentonitkadar bahan sampingandiameter , kecepatan piringan
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Pelletasi
12
University of Indonesia
Metallurgy and Materials Engineering Department UI
Pellet Bakar (Burn Pellet)
Dibakar 1000 OC, kekuatan : 2500 N/pellet
Traveling gate / conveyor belt
Grate Kiln
Shaft Furnace
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Sinter
Dalam proses ini bijih besi < 5 mm dicampur dengankokas : 8 % (bahan bakar)
air : 6-10 % (kemampuan ikat Fe tinggi)
Bahan sirkulasi : 10 – 30 %
Additiv : 5 % (CaO , Dolomit)
Dicampur (mixing drum)
Sinter machine
( lebar : ± 4 m ) kecepatan : 5 – 9 m/menit(panjang : ± 100 m)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Sinter Machine
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Sinter
14
University of Indonesia
Metallurgy and Materials Engineering Department UI
Mesin Sinter di China
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses SinterUmpan 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
dihisap
h = 40-45 cm
Terbentuk sinter pemecah ukuran 6 – 25 mm (didinginkan) < 6 mm disirkulasikan
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Sinter
University of Indonesia
Metallurgy and Materials Engineering Department UI
Lay Out Sinter Plant
16
University of Indonesia
Metallurgy and Materials Engineering Department UI
Material Batu Besi daerah Garut
University of Indonesia
Metallurgy and Materials Engineering Department UI
Material Batu Besi yang diangkut dari lokasipenambangan
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Mesin penghancur Bijih Besi
University of Indonesia
Metallurgy and Materials Engineering Department UI
Mesin Crushing/ Ball Mill
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Mesin Penghancur Bijih Besi
University of Indonesia
Metallurgy and Materials Engineering Department UI
Mesin Pencampur
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Mesin Pelletasi
University of Indonesia
Metallurgy and Materials Engineering Department UI
Dapur pembakaran pellet mentah