PROSES PEMBUATAN BAJA

DI PTKS
Karakteristik Proses & Produk Baja
• Bahan baku: besi spons
• Killed steel with low impurities (H,
N, S, P, O)
• Secondary metallurgy: ladle
furnace, vacuum degasser
• Continuous casting Produk
• Normal rolling & TMCP

• Kandungan impurities / pengotor

Proses (H, N, S, P, O) rendah
• Good internal quality
• Good cleanliness
• Kontrol komposisi ketat
• Level segregasi rendah
• Excellent mechanical properties
Produk Baja di PTKS

Produk berbeda
Produk Baja PTKS

Alur proses juga

Flat Product Long Product berbeda

HRC & CRC Wire Rod

Alur Proses Flat Product: DR, SSP, HSM
Alur Proses Flat Product: CRM
Alur Proses Long Product: DR, BSP, WRM
 Iron Making: DR Plant IRON ORE PELLET
Total Fe 67% min
SiO2 1.4% max
REFORMER CaO 1.0% max
Memecah gas alam menjadi
gas reactor (CO dan H2) H2O 2.0% max

Reaksi yang terjadi di reaktor:

Fe2O3 + CO / H2  Fe3O4 + CO2 / H2O
Fe3O4 + CO / H2  FeO + CO2 / H2O
FeO + CO / H2  Fe + CO2 / H2O

DIRECT REDUCTION IRON

Total Fe 90% min
Fe metal 83% min
Metalisasi 92% min

Kegiatan pengendalian: CaO / SiO2 0.7 min

• Analisa komposisi kimia iron ore pellet C
2.0 – 3.0%
• Kontrol proses / kondisi operasi : analisa kualitas gas (typical 2.4%)
alam , gas reformer, gas proses, temperature control P 0.05% max
• Analisa sponge iron S 0.03% max
 Steelmaking: Slab Steel Plant (SSP)

RAW & SUPP. MELTING SECONDARY CASTING SLAB INSPECTION

MATERIAL • Charging ratio METALLURGY • Temperature • Surface quality
• Chemical • Chemical comp. • Decarburization control • Internal quality
composition • Temperature • Deoxidation • Shrouding & by sulphur print
control • Desulphurization insulation / macro-etch
• Dephosphorization • Alloying • Casting parameter • Shape &
• Tap to tap time • Inclusion shape control (mold oscillation, dimension
• Temperature control casting speed)
 Steelmaking: Billet Steel Plant (BSP)

RAW & SUPP. MELTING SECONDARY CASTING BILLET INSPECTION

MATERIAL • Charging ratio METALLURGY • Temperature • Surface quality
• Chemical • Chemical comp. • Decarburization control • Internal quality
composition • Temperature • Deoxidation • Shrouding & by sulphur print
control • Desulphurization insulation / macro-etch
• Dephosphorization • Alloying • Casting parameter • Shape &
• Tap to tap time • Inclusion shape control (mold oscillation, dimension
• Temperature control casting speed)
Rolling: Hot Strip Mill (HSM)
Rolling: Cold Rolling Mill (CRM)
Rolling: Wire Rod Mill (WRM)
Hot Rolling vs Cold Rolling
Hot Rolling
Dilakukan di atas temperatur rekristalisasi
Terjadi pembentukan kristal-kristal baru selama
deformasi sehingga struktur mikro akhir tidak
memanjang
Terbentuk scale pada permukaan baja
Tidak ada internal stress
Reduksi bisa sangat besar
Cold Rolling
Dilakukan di bawah temperatur rekristalisasi
Tidak terjadi pembentukan kristal-kristal baru
selama deformasi sehingga struktur mikro akhir
memanjang dengan kenaikan kekerasan yang
signifikan
Kualitas permukaan lebih baik
Terjadi pembentukan internal stress
Reduksi terbatas
PRODUK BAJA PTKS
 Produk Utama PTKS
HOT ROLLED COLD ROLLED WIRE ROD
HRC Dimension CRC Dimension WIRE ROD Dimension
Thickness : 1.6 – 25.0 mm Thickness : 0.2 – 3.0 mm Diameter : 5.5 – 20.0 mm
Width : 600 – 2000 mm Width : 655 – 1250 mm Coil ID/OD : 860 / 1250 mm
Coil ID : 760 & 508 mm Coil ID/OD : 508 / 2000 mm Coil Height : 1000 – 1750 mm
Coil Weight : 5 – 30 MT Coil Weight : 10 - 23.4 MT Coil Weight : 1.1 – 2.2 MT

PRODUCT APPLICATION

Oil & Gas Pipes General Purposes Wire Rod

Boiler & Pressure Vessels Galvanized Sheet • General wire & nail
Gas Cylinders / LPG Bottle Pipe & Tubes • Bolt & nut
General & Welded Structures Automotive Body & Parts • High carbon application
Ship Plate & Buildings Tin Mill Black Plates • Electrode wire
General Pipe & Tubes Enameled wares • Bar in coil
Automotive Parts & Frames Steel frame housing Steel Bar
Weathering Cor. Resistant Steel Medical Bed Steel Section
Containers Grinding ball
Heavy duty vehicle & military purposes
 Produk Hot Rolled

HRC Mill
Edge

HRC Slitted /
Hot Rolled
Trim Edge /
Coil
Recoiled
Hot Rolled Products

HRC Skin
Passed

HR Plate
Hot Rolled
Plate / Sheet
HR Sheet
Hot Rolled
Pickled &
Oiled
 Spesifikasi Produk Hot Rolled
Segmen Spesifikasi Produk
API 5CT H40, J55, K55
API 5L Grade A, Grade BM,
Oil & gas Grade BN, API 5L X42 – X80
pipe (PSL1 and PSL2)
ASTM A139, DNV 485, DNV
OS F101 Grade 450
JIS G 3113 SAPH310 – 540
JIS G 3134 SPFH490 – 540
Auto-
motive JIS G 3131 SPHC, SPHD, SPHE
HSAPH540, KSAPH540,
HSAPH620
ASTM A53 Grade B
ASTM A252 Grade 1 – 3
Boiler & ASTM A283 Grade A – D
pressure
vessel & ASTM A285 Grade A – C
gas
cylinder ASTM A515 Grade 70
ASTM A 516 Grade 70
JIS G 3116 SG255, SG295
Segmen Spesifikasi Produk Segmen Spesifikasi Produk
CORTEN A – C ABS (A, AH32, AH36
Container &
JIS G 3125 SPAH BKI (Grade A, B, A32,
weathering
A36)
corrosion
BTKC Grade A, Grade B, Grade
C Ship BV (Grade A & B)
building
JIS G 3232 SPHT 1 – 4 DNV (Grade A)
SPHK 1, SPHK2 GL (Grade A & B)
Pipe & tube
KSA29H, KSA37H, KSA39H LR (Grade A)
MPW1, MPW2, MP38 SAE 1006 – 1026
AS/NZ 1594 HA250, HA350 Reroll BSEN 10111 DD11
ASTM A36, A242 Grade 2, ASTM A1006 – A1012
A284 Grade C & D, A570 Grade
30 – 50, A572 Grade 42 – 55, Floor
Checker plate
General & A573 Grade 70 plate
welded
BSEN S235 – 355 (J0, JR, J2),
structure
DIN 17100 ST37 – ST52
JIS G 3101 SS330 – 540, JIS G
3106 SM400 – SM490 (A, B, C),
JIS G 3136 SN400B, SN490B,
SNI 07 0601 BJPC, BJPS
Produk HR Berdasarkan Level Kekuatan
HR for General & Welded Structure
General application:
• Konstruksi jembatan
• Gedung / bangunan
• Konstruksi kapal, containers, tangki

Sifat baja:
• Kekuatan menengah – tinggi
• Sifat mampu las yang baik

Spesifikasi Produk

AS/NZ 1594 HA250, HA350

ASTM A36, A242 Grade 2, A284 Grade C & D,
A570 Grade 30 – 50, A572 Grade 42 – 55, A573
Grade 70
BSEN S235 – 355 (J0, JR, J2), DIN 17100 ST37 –
ST52
JIS G 3101 SS330 – 540, JIS G 3106 SM400 –
SM490 (A, B, C), JIS G 3136 SN400B, SN490B,
SNI 07 0601 BJPC, BJPS
Typical HR Structural Steel Strength Level
 HR for Oil & Gas Pipe
Produk PTKS
Sifat baja: Spesifikasi Produk
• Kekuatan API 5CT H40, J55, K55
menengah -
API 5L Grade A, Grade BM, Grade BN, API
tinggi
5L X42 – X80 (PSL1 and PSL2)
• Excellent
toughness di ASTM A139, DNV 485, DNV OS F101 Grade
450
bawah
temperatur ruang
• Excellent Range of Strength
weldability
Pengalaman PTKS Dalam Mendukung
Infrastruktur Oil & Gas
HR for Oil & Gas Pipe:
Contoh Proyek API5L X60 Sour Gas
Unsur Persyaratan Desain PTKS Unsur Persyaratan Desain PTKS
C 0.10 max 0.03 – 0.05 Cu 0.35 max 0.09 max
Mn 1.60 max 1.00 – 1.20 Ni 0.20 max 0.15 – 0.20
Si 0.40 max 0.15 – 0.20 Cr 0.20 max 0.07 max
P 0.0150 max 0.0070 max Mo 0.10 max 0.02 max
S 0.0020 max 0.0020 max Ca 0.004 max 0.004 max
Al total 0.015 – 0.050 0.025 – 0.050 B 0.0005 max 0.0005 max
N 0.0090 max 0.0070 max Nb+V+Ti 0.140 max As per actual
Nb 0.050 max 0.040 – 0.050 Cu+Ni+Cr 0.40 max As per actual
V 0.080 max 0.065 – 0.075 (Al+V+Ti)/N 2 : 1 (min) As per actual
Ti 0.020 max 0.010 max CEPCM 0.20 max 0.14 max

Kandungan pengotor rendah:

• (S) ≤ 20 ppm untuk ketahanan HIC
• (O) 10 – 40 ppm; inklusi sangat
rendah
• Kandungan H sangat rendah
• Level segregasi rendah

Komposisi kimia yang ketat

HR for Oil & Gas Pipe:
Contoh Proyek API5L X60 Sour Gas
Mechanical Properties Persyaratan Hasil
YS (Mpa) 414 – 514 (Long), 414 – 534 (Trans) 481 – 522 (HRC), 446 – 560 (Pipa)
TS (Mpa) 517 – 657 554 – 606 (HRC), 560 – 633 (Pipa)
Elongation (%) 23.6 min 32 – 40 (HRC), 26 – 40 (Pipa)
Yield Ratio 90% max 88% max
Charpy at 0 oC (Joule) 41 min 180 – 230
DWTT at 10 oC 85% min shear area 100% shear area
Hardness HV 10 250 max 180 – 220

Item Persyaratan Hasil

Pipa Spiral Pipa ERW
Item Pipa Pipa
HIC HRC HRC
NACE TM0284 Weld 0o 180o Weld 0o 180o
Solution B CSR ≤ 1.5% 0 0 0 0 0.004 0 0 0
(Cu < 0.20%)
CLR ≤ 15% 0 0 0 0 1.03 0 0 0
CTR ≤ 2% 0 0 0 0 0.13 0 0 0
Position: weld & pipe
SSCC
body
NACE TM0177
80% SMYS No No No No No No No No
Solution A
No crack crack crack crack crack crack crack crack crack
(Four point
Visual & magnetic
bending)
particle inspection
 HR for Weathering Corrosion Resistance
Application
• Pelat baja yang digunakan untuk struktur khusus yang Sifat baja:
membutuhkan ketahanan lebih tinggi terhadap korosi cuaca • Kekuatan menegah – tinggi
• Contoh: cargo container, tiang listrik, jembatan, gedung, • Good weldability
mesin industry, dll • Ketahanan lebih tinggi
terhadap korosi cuaca

Tipikal Komposisi Kimia Produk PTKS

Spesifikasi Produk Spec.
C Si Mn P S Cu Ni Cr V
CORTEN A – C BTKC-A / SPAH 0.07 0.45 0.45 0.10 0.010 max 0.35 0.25 0.80 -
JIS G 3125 SPAH BTKC-B 0.15 0.50 0.90 0.020 max 0.020 max 0.35 0.25 0.45 0.045

BTKC Grade A, B, C BTKC-C 0.15 0.50 1.10 0.020 max 0.020 max 0.35 0.25 0.45 0.060
HR for Pipe & Tube
Aplikasi:
• Small-medium welded pipes
& tubes for line pipes,
furniture, frames,
automotive parts, etc

Sifat baja:
• Kekuatan rendah -
menengah
• Good formability &
bendability
• Good weldability

Spesifikasi Produk
JIS G 3232 SPHT 1 – 4
SPHK 1, SPHK2
KSA29H, KSA37H, KSA39H
MPW1, MPW2, MP38
HR for Automotive
Aplikasi:
• Frame (cross-member, chasis),
automobile wheel disc, oil filter, fuel
tank for truck/bus, tank

Sifat baja:
• Kekuatan menengah – tinggi
• Excellent weldability
• Good fatigue resistance

Spesifikasi Produk
JIS G 3113 SAPH310 – 540
JIS G 3134 SPFH490 – 540
JIS G 3131 SPHC, SPHD, SPHE
HSAPH540, KSAPH540,
HSAPH620
SPH270COD, SPH440OD
HR for Boiler & Pressure Vessel
Aplikasi: Spesifikasi Produk
• Bejana tekan, vessel untuk industry kimia, pembangkit,
dll yang beroperasi sampai temperature tinggi, tabung ASTM A53 Grade B
gas untuk rumah tangga dan industri ASTM A252 Grade 1 – 3
ASTM A283 Grade A – D
Sifat baja:
• Kekuatan menengah – tinggi ASTM A285 Grade A – C
• Excellent weldability ASTM A515 Grade 70
• Good toughness
• High resistance at elevated temperature (high creep ASTM A 516 Grade 70
resistance) JIS G 3116 SG255, SG295
HR for Shipbuilding Spesifikasi Produk
ABS (A, AH32, AH36
Aplikasi:
BKI (Grade A, B, A32, A36)
• Welded steel plate untuk bangunan kapal dan
BV (Grade A & B)
konstruksinya (termasuk repair dan equipment),
instalasi lepas pantai, dan struktur maritime lainnya DNV (Grade A)
GL (Grade A & B)
Sifat baja: LR (Grade A)
• Kekuatan menengah – tinggi NKK (KA, KA32, KA36)
• Excellent weldability
• Good fatigue resistance
• Good toughness
 HR Checker Plate
Aplikasi:
• Rak, tool box, panel lift,
electronic cabinets
• Pelat untuk lantai pada
tangga atau aplikasi lain
yang memerlukan
ketahanan selip & mudah
dibersihkan

Sifat baja:
• Kekuatan rendah –
menengah
• Good weldability &
formability
Strip Checker
Thickness Height
(mm) (mm)
t<3 1.0 min.
3≤t<5 1.3 min.
5≤t<7 1.5 min.
t≥7 1.7 min.
High Strength Low Alloy (HSLA) Steels
Sifat baja HSLA: Thermo-Mechanical Control Process (TMCP)
• High strength
• Good formability
• Good toughness
• Good weldability
• Good corrosion
resistance

Karakteristik:
• %C rendah (kisaran 0.10
atau lebih rendah)
• Paduan mikro (Nb, V, Ti)
rendah (0.01 – 0.10%)
• Ukuran butir halus dan
struktur mikro seragam

Ukuran butir halus – struktur mikro seragam

Baja HSLA PTKS
 Produk Cold Rolled
Annealed CRC Steel

Cold Rolled
Annealed CR Sheet
Products

Full Hard & As-Rolled

CRC
 Spesifikasi Produk Cold Rolled

Aplikasi CR:
• General purpose
• Galvanized sheet
• Pipe & tube
• Automotive body &
parts
• Tin mill black plate
• Home & office
appliances
• Enamelwares
Produk CR Berdasarkan Level Kekuatan
CR for General Purposes
Aplikasi: Spesifikasi Produk
• Penggunaan umum steel sheet
JIS G 3141 SPCC-1D, SPCC-SD
antara lain: sheet cover, drums,
office cabinet & appliances, zinc or SNI 07 3567 BjDC
zincalume coated roofing Atau equivalen

Sifat baja:
• Kekuatan rendah
• Low to medium formability &
bendability
• Good weldability
CR for Pipe & Tube
Aplikasi:
• Pipa dan tube kecil untuk structural Spesifikasi Produk
dan non-structural seperti
furniture, automotive frame & MP1A, MP1C, MP38
parts, dll SPCC-SD, SPCCT-SD, KSA29C,
KSA37C, KSA39C
Sifat baja: KSSTA290, KSS37C, KSSTA390
• Kekuatan rendah – menengah
• Medium formability & bendability SPCK-4, SPCK-5
• Good weldability Atau equivalen
• Good surface appearance
CR for Automotive Body & Parts
Aplikasi:
• Structural & non-structural, exposed & unexposed
automobile body, motorcycle frame, fuel tanks,
oil filter, air filter, lamp reflector, dll

Sifat baja:
• Kekuatan rendah – menengah
• Good to excellent formability & drawability
• Good weldability
• Excellent surface appearance & cleanliness

Spesifikasi Produk
ASTM A1008M 01a CS/DS Type A, B, C
DIN 1623 Part 1 ST13
JIS G 3141 SPCD, SPCE,
SPC270C, SPC270D
Atau equivalen
CR for Enamelware
Aplikasi:
• Single, double, and multi-layer enamelware
seperti mangkuk, gelas/mug, alat masak, ceret, Spesifikasi Produk
wadah makanan, penggorengan JIS G 3133 SPP
JIS G 3141 SPCC-SD
Sifat baja:
• Kekuatan rendah Atau equivalen
• Good to excellent formability & drawability
• Good weldability
• Good enamelability
CR for Tin Mill Black Plate
Aplikasi:
• Blackplate for tinplate application seperti kaleng
umum, kaleng makanan, kaleng bahan kimia, dll
Spesifikasi Produk
Sifat baja: JIS G 3303 SPB-MR T2.5, T3,
• Kekuatan rendah – menengah T4
• Good formability & bendability Atau equivalen
• Good weldability
• Good surface appearance & cleanliness
CR for Steel Frame Housing
Aplikasi:
• Structural and non-structural housing frame Spesifikasi Produk
seperti rangka atap, dinding, jendela, lantai, dll
JIS G 3141 SPCC-1D, SPCC-2D,
SPCC-SD
Sifat baja:
• Kekuatan menengah – tinggi SPC G300, SPC G550
• Relatively low formability & bendability Atau equivalen
• Good weldability
Spesifikasi Produk Wire Rod

Segmen Spesifikasi Produk Aplikasi

Low & medium
JIS G 3505 SWRM 6, 8, 10, 12, 15, 17, 20 General drawing application, wire mesh
carbon

JIS G 3506 SWRH 42A, 62A, 62B, 67A, Umbrella ribs, helical wire, spring wire, wire
High carbon
67B, 72A, 72B, 77B, 82B rope, PC strand, PC wire

JIS G 3503 SWRY11, IEW 649 FI, EW 2616

Electrode Core Wire Wire rod for core of covered electrode
B, EW 1804 A, ER 705-3

Cold heading JIS G 3507 SWRCH8A, 10A, 12A, 18A Cold heading & cold forging end use

Concrete reinforce JIS G 3112 SR 24, SD 40 Concrete reinforcement bar

Shafting bar JIS G 4051 S30C, S35C S45C Carbon steel for shafting bar

Grinding ball SAE 5052 Alloy steel for grinding ball

Produk WR Berdasarkan Level Kekuatan
WR for General Wire & Nail
Aplikasi:
• General wire, nail, wire mesh, general
fastener, dll Spesifikasi Produk
JIS G 3505 SWRM6, 8, 10, 12,
Sifat baja: 15, 17, 20
• Kekuatan rendah – menengah
• Good formability & drawability Atau equivalen
• Good weldability
WR for Bolt & Nut
Aplikasi:
• Small to medium diameter cold-
headed rods seperti medium-heavy
duty bolts & nuts

Sifat baja:
• Kekuatan rendah – menengah
• Good formability & drawability
• Good weldability
• Excellent cleanliness

Spesifikasi Produk
JIS G 3507 SWRCH8A, 10A,
18A
Atau equivalen
WR for High Carbon Application
Aplikasi:
• High carbon wire for springs, pre-
Spesifikasi Produk
stressed concrete (PC) wires, wire
ropes, spoke wires, dll JIS G 3506 SWRH42A, 62A, 62B, 67A, 67B,
72B, 77B, 82B
Sifat baja: Atau equivalen
• Kekuatan menengah – tinggi
• Medium formability & drawability
• Good weldability
• Excellent cleanliness
WR for Electrode Core Wire
Aplikasi:
• General covered electrode wire for arc
welding Spesifikasi Produk

Sifat baja: JIS G 3503 SWRY11, SWRY21

• Kekuatan rendah Atau equivalen
• Medium formability & drawability
• Good weldability
• Special chemical composition