BIJIH BESI & AGLOMERISASI

Prof. Dr.-Ing. Bambang Suharno

Metallurgy and Materials Engineering Department

University of Indonesia
2010

Bahan Baku Proses Pembuatan Besi

University of
Indonesia
Baja
 Iron Ore
 Reduktor
 Coke (Blast Furnace)
 Coal (Reduksi Langsung dan Smelting
Reduction)
 Natural Gas (CH4) (Reduksi Langsung)
 Scrap
 Additive (Flux): CaO

Metallurgy and Materials Engineering Department UI

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University of
Jenis Bijih Besi (Iron Ore)
Indonesia

 Jenis oksida (terbanyak) 
Magnetit  Fe 
(Fe3O4 ==  Magnetit Fe ≈ 72,4 %
72 4 %
Fe2O3 =  Hematit Fe ≈ 70 %
 Jenis Hidroksida  Fe ≈ 50 % ‐ 55 %
Fe2O3.nH2O =  Hydrohematite/Laterit 
Fe2O3*H2O =  Goethit 
Fe2O3*3 H2O    =  Limonit 
 Jenis karbonat
FeCO3 Siderit  Fe 
=  Siderit    Fe ≈ 48,2 %
48 2 %
 Jenis Titanious Ferrous 
FeO.TiO2 =  Pasir Besi/Ilmenit  Fe ≈ 36,8 %,  Ti ≈ 5‐13 %
 Jenis Sulfit 
(FeS2 =  Sulfit  Fe ≈ 46,7 %

Metallurgy and Materials Engineering Department UI

University of
Jenis Bijih Besi
Indonesia

Goethite Limonite Magnetite

Metallurgy and Materials Engineering Department

Hematite HematiteUI Hematite

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University of
Karakteristik Mineral Iron Ores
Indonesia

Metallurgy and Materials Engineering Department UI

Chemicals composition of iron ores

University of
Indonesia
from various countries (wt %)

Metallurgy and Materials Engineering Department UI

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University of
Indonesia

Metallurgy and Materials Engineering Department UI

Iron ore production

million metric tons
University of (2004)
Indonesia

Metallurgy and Materials Engineering Department UI

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University of
Persyaratan Bijih Besi
Indonesia

 High Iron content

 Minimum
Minim m imp
impurities
rities (S
(S, P
P, As
As, Zn
Zn, Pb
Pb, Na
Na, K
K,))
 High content of basic oxides in gangue (self fluxing
ore)
 Minimum derivation in chemicals composition
 High reducability
 High
g strength
g
 Minimum of fines and narrow size distribution (for a
uniform gas flow)

Metallurgy and Materials Engineering Department UI

Sebaran Bijih Besi Lokal

University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 11

University of
Deposit Bijih Besi Indonesia
Indonesia

Sumber Daya Terukur

Jenis Deposit Bijih
Besi
Ton Lokasi

Lampung, West of Sumatera,

Methasomatic Ore 320.462.611 Belitung, west of Kalimantan,
Tanalang, Plaihari, dll.

South of Kalimantan,, Pomalaa,,

Lateritic 1 391 246 630
1.391.246.630
Halmahera, dll.

South of Java Island Coast,

Iron Sand 382.000.000 Sumbar, Bengkulu, NTB, Sulsel
dll.
Sumber : Direktorat Mineral Batubara ESDM

Metallurgy and Materials Engineering Department UI

University of
Bijih Besi Sekitar Lampung
Indonesia

Metallurgy and Materials Engineering Department UI

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 Sebaran Batu Bara Lokal
University of
Indonesia

1.000 juta ton

3.000 juta ton

10.000 juta ton

20.000 juta ton “Batubara kualitas Bituminous banyak terdapat di Kalimantan

Timur”

Metallurgy and Materials Engineering Department UI

Deposit Batubara
University of
Indonesia
(sumber C atau CO sebagai zat pereduksi)

Metallurgy and Materials Engineering Department UI

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 PENINGKATAN NILAI JUAL MULAI BAHAN BAKU SAMPAI PRODUK JADI PADA
INDUSTRI BESI BAJA
University of
Indonesia

800
700
HRC
600
SLAB
500
$ / TON

400 PIG IRON

300
200 PELET
KONS
100
ORE
0
1 2 3 4 5 6

Metallurgy and Materials Engineering Department UI PT KRAKATAU STEEL

Bijih besi

University of
Indonesia Fe tinggi Fe rendah

Pemurnian
> 6 mm < 6 mm
konsentrat ( Fe tinggi )
ukuran rendah

Aglomerisasi (Pellet , Sinter)

> 6 mm
Lump ore

Export
Blast Furnace = Pig Iron (Hot Metal)
Reduksi Langsung = Sponge Iron Pellet

Ukuran 6 mm  batas undersize yang masih dapat diolah

Umumnya berukuran 12 – 30 mm

Metallurgy and Materials Engineering Department UI

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University of
Proses pemurnian Bijih Besi
Indonesia

 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)
 Magnetic separator
 Flotation
 Iron ore yang sudah dimurnikan disebut
“KONSENTRAT”

Metallurgy and Materials Engineering Department UI

Crushing dan Screening

University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 Milling dan Spiral Classifier
University of
Indonesia

Metallurgy and Materials Engineering Department UI

Magnetic Separator Process

University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 Bahan Baku Pasir Besi (Raw
University of
Indonesia
Material)
• Sumber bahan baku Cipatujah, Tasikmalaya berada di
p Ciheras, Cimanuk, Cikaung
lokasi: Cidadap, g Gading.
g

• Kandungan
• Fe = 35-40%
• TiO2 = 5 – 15%
Cidadap Ciheras

Cimanuk Cikaung Gading
Metallurgy and Materials Engineering Department UI

Konsentrat Pasir Besi (Ore

University of
Indonesia
Treatment)
Pasir Besi

Magnetic Separator

Konsentrat

CMPFA Metalurgi UI

Metallurgy and Materials Engineering Department UI

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 Spiral
Classifier
University of
Indonesia

Metallurgy and Materials Engineering Department UI

Iron Ore Dressing

University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 Pengolahan Latheritic Ore di Indonesia
University of
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
2. PT. SILO (Sebuku Iron Lateritic Ores)
- Project began : 2000 (actual start-up 2003)
- Kapasitas : 2,000 – 2,500 ton per hari

Metallurgy and Materials Engineering Department UI

University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 Mining & Processing Operations
University of
of Latheritic Ore in Indonesia
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Indonesia

LATERITE IRON ORE
Metallurgy and Materials Engineering Department UI

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University of
Indonesia

BIJIH BESI KARUNGAN
Metallurgy and Materials Engineering Department UI

University of
Indonesia

IRON ROCK
Metallurgy and Materials Engineering Department UI

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University of
Pengolahan Bijih Besi
Indonesia

Sinter

Fe tinggi

Iron ore Lump ore

Blast F’ce Foundry

Pig Iron
Pellet
Ukuran halus
Fe rendah

First Step : Tentukan Steel Plant

Red Lgsng
Kualitas dan Kuantitas
Cadangan Bijih Besi
Sponge Iron
Metallurgy and Materials Engineering Department UI

University of
Alasan Aglomerisasi
Indonesia

 Tidak semua bijih besi memiliki kadar Fe

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
 Ukuran partikel kecil , menyebabkan adanya
sejumlah fine material yang keluar tanur dan
masuk ke ‘gas recovery’ system

Metallurgy and Materials Engineering Department UI

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University of
Proses Aglomerisasi
Indonesia

 Kriteria pemilihan
 ukuran partikel > 2 mm 
sinter
 ukuran partikel < 0,2 mm 
pellet
 Lokasi Pembuatan
 Sinter  biasanya dekat TT
 Pellet
P ll t  biasanya
bi d
dekat
k t
penambangan

Metallurgy and Materials Engineering Department UI

University of
Penggunaan Pellet dan Sinter
Indonesia

 Europa Union : 65% sinter, 24% pellet, 13%

lump 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%
 Pada blast furnace sebetulnya
memungkinkan untuk mengolah bijih besi
dengan berbagai kadar Fe. Namun semakin
tinggi kadar Fe akan semakin ekonomis
Metallurgy and Materials Engineering Department UI

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University of
Proses Pembuatan Pellet
Indonesia

 Dikembangkan dalam rangka pemanfaatan bijih besi

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)
 bola-bola aglomerat dikeraskan dengan cara dibakar
pada: conveyor belt, grate kiln atau shaft furnace
 (kekuatan hingga 2500 N/ pellet)

Metallurgy and Materials Engineering Department UI

University of
Pellet Mentah (Green Pellet)
Indonesia

Bijih besi halus dengan campuran

Bentonit : 8,3
8 3 - 10 kg/ ton of feed
% air : (4-7%)

ukuran pellet : ± 8 – 30 mm
β  biasanya 10 – 15 mm

Kekuatan Green pellet :

20 – 50 N / pellet

Metallurgy and Materials Engineering Department UI

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University of
Pelletasi
Indonesia

Faktor penentu
 kadar air harus optimal
 kehalusan partikel
 penambahan bentonit
 kadar bahan sampingan
 diameter , kecepatan piringan

 jika kekuatan green pellet rendah  dibakar (T = 1000 oC)

 agar kekuatan : 2500 N/pellet
 Alat : Shaft furnace
Grate kiln
Traveling gate / conveyor belt
Metallurgy and Materials Engineering Department UI

University of
Proses Pelletasi
Indonesia

Metallurgy and Materials Engineering Department UI

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 Parameters of the discs for
University of
Indonesia
production of green pellet

Metallurgy and Materials Engineering Department UI

University of
Pellet Bakar (Burn Pellet)
Indonesia

 Dibakar 1000 OC, kekuatan : 2500 N/pellet

Grate Kiln

T
Traveling
li gate
t / conveyor belt
b lt

Shaft Furnace

Metallurgy and Materials Engineering Department UI

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University of
Campuran Sinter
Indonesia

 Iron bearing fines ( 50-60% of raw mix, grain sixe 0-

10 mm, incl. 70%>
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)
 Return sinter fines (25-35%, grain size < 6.3 mm)
 Moisture (water 5-9%)

Metallurgy and Materials Engineering Department UI

University of
Proses Sinter
Indonesia

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)

Dicampur (mixing drum)

Sinter machine
( lebar : ± 4 m ) kecepatan : 5 – 9 m/menit
(panjang : ± 100 m)

Metallurgy and Materials Engineering Department UI

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University of
Sinter Machine
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Proses Sinter
Indonesia

Metallurgy and Materials Engineering Department UI

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University of
Produk Sinter
Indonesia

Metallurgy and Materials Engineering Department UI

Requirements on physical and

University of
Indonesia
metallurgical properties of sinter

Metallurgy and Materials Engineering Department UI

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 Operation Data of Sinter Plant in
University of
Indonesia
Germany

Metallurgy and Materials Engineering Department UI

European
University of sinter plants
Indonesia

Metallurgy and Materials Engineering Department UI

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University of
Mesin Sinter di China
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Annular Sinter Maschine
Indonesia

Metallurgy and Materials Engineering Department UI

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University of
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Proses Sinter
Indonesia

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

dihisap Terbentuk sinter  pemecah  ukuran 6 – 25 mm (didinginkan)

< 6 mm  disirkulasikan

Metallurgy and Materials Engineering Department UI

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University of
Proses Sinter
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Indonesia

Lay Out
Sinter Plant

Metallurgy and Materials Engineering Department UI

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University of
Sinter capacities (million t/a)
Indonesia

Metallurgy and Materials Engineering Department UI

Material Batu Besi daerah Garut

University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 Material Batu Besi yang diangkut dari lokasi
University of penambangan
Indonesia

Metallurgy and Materials Engineering Department UI

Mesin penghancur Bijih Besi

University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 Mesin Crushing/ Ball Mill
University of
Indonesia

Metallurgy and Materials Engineering Department UI

Mesin Penghancur Bijih Besi

University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 Mesin Pencampur
University of
Indonesia

Metallurgy and Materials Engineering Department UI

Mesin Pelletasi
University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 Dapur pembakaran pellet mentah
University of
Indonesia

Metallurgy and Materials Engineering Department UI

Generator Listrik
University of
Indonesia

Metallurgy and Materials Engineering Department UI

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 SOLUSI TEKNOLOGI PENGOLAHAN BIJIH BESI LOKAL

Iron Ore
University of
Indonesia Low Grade High Grade

Rute proses PIBB

Crushing Crushing
Size:
0.08-0.17mm
Beneficiation Screen
Grinding
Coal Concentrate Lump <6mm
(Fe>65%) 6-25mm
Binder

Pelletizer Sintering
Pellet
Coke
Mixer Grate-Rotary Kiln Natural
Binder Indurator Gas

Pelletizer Coal

Rotary Kiln Direct

Blast Furnace
Fasmet, Reduction
ITMK3,Inmetco,
Comet DRI DRI Pig Iron DRI
Coal Base Gas Base
Metallurgy and Materials Engineering Department UI

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