Peleburan Bijih Nikel

(Pirometalurgi)

29 Maret 2018
 Produksi Nikel dan Harga Nikel
2.4 70000
World nickel production
2.2
Indonesian export (ore) + inland production 60000
2.0
Indonesian inland production
1.8 Nickel price
50000
Nickel Production (mio. tons)

Nickel pricce (USD/ton)

1.6

1.4 40000
Export ban of
1.2 Indonesian ore

1.0 30000

0.8
20000
0.6

0.4
10000
0.2

0.0 0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
Year

Minerba, ESDM, RI http://www.infomine.com https://www.statista.com https://minerals.usgs.gov

29 Maret 2018 Zulfiadi Zulhan 2
 Profil Deposit Bijih Nikel Laterit dan Teknologi
Pengolahan
MgO, Fe2O3, SiO2 (%)
Pyrometallurgy
0 10 20 30 40 50 60 70 80

Iron cap, Ferricrete

0.01% Co

Smelting: Blast Furnace

H2SO4 leach
Limonite 0.15% Co

HNO3 leach (DNi)

Smelting: RK-EF
Saprolite 0.05% Co

0.01% Co Hydrometallurgy
Bedrock
http://www.panoramio.com 0 1 2 3 4 5 6 7
Ni, Cr2O3, Al2O3 (%) After Brand et.al. 1998

The selection of the technology is dictated by the ore characteristic, especially the chemical
composition and the product of the processing plant
29 Maret 2018 Zulfiadi Zulhan 3
 Teknologi untuk Memproses Bijih Nikel Laterit
Hydro
meta
llurgy
37%

Hydrometallurgy:
H2O = {H2O} 200 C

e2O3> + {CO} = 2<Fe3O4> + {CO2}

C
Fe2ONiO
3 Fe2O3
C C C
H2O C
6-8 hours, burden from top to
tuyere level
recover Ni and Co
CO} = {CO2} + <C>

e3O4> + {CO} = 3<FeO> + {CO2} Fe3O4 Fe3O4 <FeCO3 >= <FeO> + {CO2}
CO2
800 C CO2 CaO CO2 <CaCO3 >= <CaO> + {CO2}
FeO FeO
e3O4> + 4{CO} = 3<Fe> + 4{CO2} CO CO <NiO> +CO = <Ni> + {CO2}
O> + {CO} = <Fe> + {CO2}
CO CO FeO + {CO} = Fe + {CO2}
FeO
> 1000 C Fe Ni
Fe Fe Fe {CO2} + <C> = 2{CO}
C = <Ni> + {CO} FeAl2O3 CaO P2O5Fe SiO2 + 2<C> = [Si] + 2{CO}
} + <C> = 2{CO} CaS MgO SiO2 Cr2O3
CO CO Cr2O3 + 3<C> = 2[Cr] + 3{CO}
} + <C> = {CO2} CO C Fe Si CO

Luppen FeNi
Fe Ni Cr <C> = [C]
1800-2000 C N2 O2 S P O2 N2 MgO+SiO +CaO+Al O
2 2 3
1500 C
dence time of gas:
seconds or more 1400 C

NPI Pyrom
etallu
Mini Blast Furnace Nippon Yakin Oheyama 63% rgy
(MBF) Process (Krupp-Renn)
11% 2%

S: Z. Zulhan, 2017

FeNi,
Rotary Kiln - Electric Ni matte,
RHF – RIBF? Furnace (RKEF)
87% NPI
Electric Furnace
29 Maret 2018 Zulfiadi Zulhan 4
 Teknologi untuk Memproses Bijih Nikel Laterit
Technology Comments
RKEF (Rotary Kiln – Electric (+) Proven technology
Furnace) (+) a lot of reference plants
(-) using electricity for smelting
BF (Blast Furnace) (+) Proven technology for mini blast
furnace
(+) some reference plants
(-) high coke consumption
Rotary Kiln / Krupp Renn (Luppen) (+) Proven technology
(-) one reference plant in Japan
(-) slag ring formation
Rotary Kiln (Sponge Nickel Iron) (-) one reference plant in Indonesia
RHF – RIBF (Rotary Hearth Furnace (-) lack of reference plant
– Regenerative Iron Bath Furnace)

29 Maret 2018 Zulfiadi Zulhan 5

 RKEF and BF Plants in Indonesia
Since 2015

RKEF

Since 1974
RKEF

Since 2013
BF

Since 1979
RKEF

29 Maret 2018 Zulfiadi Zulhan 6

Perbandingan RKEF dan MBF
Technology RKEF Mini BF
Equipment Rotary dryer-rotary kiln-electric Sintering – blast furnace –
furnace (coking plant)
Electrical energy High for smelting in electric Relatively low for turbo
consumption furnace and for equipment blower and other equipment
Coke consumption Not required. There is a trend to High for smelting and
use semicoke reductant
Coal consumption Low, for reductant and fuel for Anthracite coal or coke
rotary dryer and rotary kiln breeze for sintering
Ni content in the < 40% < 15%
product
Productivity per line or High (power furnace up to 100 Low (inner volume of blast
per furnace MW) furnace < 500 m3)
Capex High Low
Opex Depending on electricity price Depending on coke price

S: Z. Zulhan, 2017

29 Maret 2018 Zulfiadi Zulhan 7

 New Concept for Ferronickel Production
RKSR (Draf Paten, Z. Zulhan 2013) 1
11
9 8 9 7 7
3
12 1 9 9 7 10
3 3a
3a
2
4
2
4 4 4
5
5 5
6 6 5
6 6

16
19

17
18 1
15 15
15 3

14
13 2
3 4 4
1 2
12 11 4
5
5
5
6 6
20
23 22
21

S: Z. Zulhan, 2013
29 Maret 2018 Zulfiadi Zulhan 8
Perbandingan: RKEF, BF, RKSR
RKEF BF RK – SR
Coal Coking coal Coal

Electricity Coking RK - SR
Eff ~ 30% Plant

-By product (COG),

RD – RK – EF tar, etc..
- Steam

Coal for drying in RD, Blast

reduction and heating in Furnace
RK and further reduction
in EF
S: Z. Zulhan, 2014

29 Maret 2018 Zulfiadi Zulhan 9

 Model Blast Furnace

S: Z. Zulhan, 2013

29 Maret 2018 Zulfiadi Zulhan 10

 Model Blast Furnace
: Mass Balance
11 12 13 14 15 16 17 18 19
al Slag Dust
3.00 4.91 2.09
8.00
0.00 2.087332054
p Temp oC
1 Dry Top Gas 6.02 ton
200
1 Moisture 0.03 ton
1 Dust 0.05 ton 180
Dry gas (% Vol.) Wet gas (% Vol.)
%CO 27.88 %CO 27.66
%CO2 11.44 %CO2 11.35
%N2 58.02 %N2 57.56
%H2 2.65 %H2 2.63
%H2O 0.79
0.662517932

Temp oC 1500
Slag 0.54 ton 99.96
%CaO 20.58 %P2O5 0.00 Ton CaO 0.11 Ton P2O5 0.00
2518 %SiO2 31.06 %Cr2O3 3.90 Ton SiO2 0.16 Ton Cr2O3 0.02
%Al2O3 31.75 %FeO 0.14 Ton Al2O3 0.16 Ton FeO 0.02
%MgO 11.74 %TiO2 0.00 Ton MgO 0.06 Ton TiO2 0.00
%MnO 0.40 %NiO 0.38 Ton MnO 0.00 Ton NiO 0.00
B=(%CaO + %MgO)/%SiO2 1.04
Slag viscosity 0.28 dPa.s 43.03181 42.43883033

Temp oC 1400 43.03181 42.43883033

Metal 1.00 ton
%Ni 2.89 %Cr 1.41 56.69754 32.25845452
%C 4.52 %P 0.03
%Si 0.95 %S 0.23 63.41529 36.08056828
%Mn 0.58 %Fe 89.32
2.07 %Co 0.08
o
OI Liquidus Temperature 1303 C

100.00 89.32

S: Z. Zulhan, 2013

29 Maret 2018 Zulfiadi Zulhan 11

 Model Blast Furnace
Cal.Dim.
BLAST FURNACE: Dimension and Productivity
15 12 13
Inner Volume (Set Point) 1800 m3 0.85 2886
Cal.Value
14
Inner Diameter Cal Input Unit Inner Volume 129.12 m3
Throat 7.22 2.59 m 2.59 13 Working Volume 129.12 m3
Belly 10.46 4.00 m 4.00 Productivity 0.49 t/m3/day
Hearth 9.49 3.32 m 3.32 Productivity calculated. 0.49 t/m3/day 280.800.00
12
Troat Length 1.28 m 1.28 -1.2971 14.263 Production metal 63.24 t/day 3.312
Shaft Length 15.27 6.75 m 6.75 -1.2971 12.988 44.265.57 3.311.64 105.352.07 3.312 35
Belly Length 3.21 1.68 m 1.68 -1.9975 6.239 11 Operation day in a year 350 day 391.307.68 2.500.000 26.482
Bosh Length 1.93 2.38 m 2.38 -1.9975 4.556 Production 22.133 t/year 44.265.57 1.679.166 584.041.31
Hearth Length 4.17 2.18 m 2.18 -1.6575 2.176 10 Dry Ore 195.654 t/year Wet Ore 292.021 t/year
o
Shaft Angle 87.37 85.00 85.00 -1.6575 0 Sinter 209.896 t/year 599.70 t/day 24.99
o
Bosh Angle 80.00 80.00 1.6575 0 9 Coke 52.676 t/year 150.50 t/day 6.27
Inner Height 24.58 14.26 m 1.6575 2.176 Coal - t/year 0.00 t/day 0.00
Vol. Hearth 18.78 18.78 m3 3.05 1.9975 4.556 8 Blast air 244.697 t/year 699.13 t/day 29.13
Vol. Bosh 24.97 24.97 m3 4.70 1.9975 6.239 Blast air 203.901.044 Nm3/year 582.574.41 Nm3/day 24.273.93
Vol. Belly 21.10 21.10 m3 3.90 1.2971 12.988 Flux (limestone) 35.855 71710.23 3.311.64
7
Vol. Shaft 57.54 57.54 m3 1.50 1.2971 14.263 Metal 22.133 t/year 63.24 t/day 2.63
Vol. Throat 6.74 6.74 m3 7.94 Slag 164.560 t/year 470.17 t/day 19.59
Calculated Inner Volume 129.12 129.12 m3 1.98 6 Off-gas 308.390 t/year 881.11 t/day 36.71
2.80 Off-gas 424.465.535 m3/year 1.212.758.67 m3/day 50.531.61
2.56 5 Off-gas 267.422.261 Nm3/year 764.063.60 Nm3/day 31.835.98
Metal Density 7.00 ton/m3 61.637.53
Tuyere 2
Slag Density 3.00 ton/m3 6.37E+04
4
Metal Height 0.17 m 4.00 Hr
Slag Height 1.51 m 2.00 Hr

Nickel Pig Iron [ton]

1.03 3
Metal Tapping Hole 0.00 m from Hearth bottom
1
Slag Tapping Hole 0.00 m from Metal Tapping Hole 2

No. Tuyerem (M.A. Pavlov) 8 Tuyere Distance (m) 1.27 1

No. Tuyerem (O. Rice) 8 Tuyere Distance (m) 1.27
0 0
-3 -2 -1 0 1 2 3 -2 -1 0 1 2

-1.6575 0.17445
-1.6575 0
1.6575 0
1.6575 0.17445 -1
-1.6575 0.17445

S: Z. Zulhan, 2013 -2

29 Maret 2018 Zulfiadi Zulhan 12

 Model Blast Furnace
15
15
16 3500 14
14

13 14 3000
13

12
12

12 11
11
2500
10
10
10
9 2000 9

8 8 8

7 1500 7

6
6 6

5 1000 5
4
4
4

3 2 500 3

2
2

1
0 - 1

0
0 20 40 60 80 100 0
-3 -2 -1 0 1 2 3
-3 -2 -1 0 1 2 3
% Limonite in the Blending Limonite
Saprolite

%Ni in NPI Dry Ore (ton/ton NPI)

Slag (ton/ton NPI) Ni production (ton/year)
Coke consumption (kg/ton NPI)

S: Z. Zulhan, 2013 S: Z. Zulhan, 2013

29 Maret 2018 Zulfiadi Zulhan 13

 Model RKEF
ORE COMPOSITION
Mix USD
ORE %Ni %Co %Fe %SiO2 %CaO %MgO %Al2O3 %P2O5 %Cr2O3 %SO2 LOI % H2Ofree S/M M/S Fe/Ni %NiO %CoO %Fe2O3 %H2O(LOI) Total Ratio (%) to
Limonite 1.49 0.05 48.33 2.35 0.00 0.36 6.54 0.02 2.21 0.04 17.42 34.00 6.45 0.16 32.44 1.90 0.06 69.10 23.39 100.00 10.00
Saprolite 1.82 0.02 8.65 39.40 0.36 23.10 1.89 0.02 0.47 0.04 20.01 34.00 1.71 0.59 4.75 2.32 0.03 12.37 4.19 100.00 90.00

Mixing 1.79 0.03 12.62 35.70 0.32 20.83 2.35 0.02 0.65 0.04 19.75 34.00 - - 1.71 0.58 7.06 2.27 0.03 18.04 6.11 100.00 100.00 -

Dust RD 2.00% 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Dust RK 15.00%
Clinker 0.18% 4 5 6 8 9 10 11 Losses 13 14 Losses 16 17
Ni Rec EF 94.71% 94.709999003 0.00 0.50
Dust EF 0.50%
Refining Rec 100.00% EF RK RD Dust Briquetting
Slag treatment rec 0.00% 26.83% 73.17% 2
Shot Making 100.00%
Ore Biquette
100 Rotary Dryer Rotary Dryer 19.65
Conditioned Ore RK Dust
1.00 98 17.65

RotaryKiln
Rotary Kiln
0.559254031 Calcined Ore
De-S Slag (-50mm) 99.79
0.00
Check Clinker EF Dust
Briquetting 0.000000000000 0.21 0.50
Rotary Kiln 0.000000000000
Electric Furnace 0.000000000000
Refining 0.000000000000 De-S Slag (+50mm) Electric
Electric
Shotmaking 0.000000000000 0.00 Furnace
Furnace
Slag treatment 0.000000000000 Slag
4.79
Final Slag Slag Slag Ref Crude FeNi
Refining
0.00 Treatment 0.00 94.71

Developed by:
Zulfiadi Zulhan FeNi
94.71

Shot reject
Shot Making 0.00

FeNi S: Z. Zulhan, 2014/2017

94.71

29 Maret 2018 Zulfiadi Zulhan 14

 Model RKEF MASS BALANCE: ROTARY DRYER MASS BALANCE: ROTARY KILN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
1 2 3 4 5 6 7 8 9 10 11 12 13 14 OFF GAS Conditioned Ore Reductant Coal Limestone Basicity Primary Air Fuel Coal
o o o o o o
C Temp 28 C Temp 28 C Temp 28 C CaO/SiO2 0.01 Temp 28 C Temp 25 C
Ore Temp 200
o T/h % LP T/h % ZZ T/h % T/h Nm3/h % Vol T/h %
Temp 28 C T/h Nm3/h % LP
Total wet 61.04195 100.00 59.06 Total 3.21 7.58 Total 0.00 100.13 Primar. Air 1.3 Total 66.60 56.578 100.00 Total 3.93 84
T/h % Rotary Dryer Total 15.58 18.582.57 100.00 91.848.69 NiO 1.08 2.30 Selisih FC 1.28 39.96 2.9125964 CaCO3 0.00 96.57 O2 15.18 11.599 20.50 FC 1.57 39.96
Total wet 79.06 100.41 CO 0.00 - 0.00 Ni 0.00 0.00 1.981411 VM 0.88 27.44 -4.37 MgCO3 0.00 2.43 Fuel coal iteration N2 51.21 44.697 79.00 VM 1.08 27.44
Fe2O3 5.80 12.33 Coal dust Ash 0.18 5.60 SiO2 0.00 0.73 from 1 H2O 0.21 283 0.50 Ash 0.22 5.60
NiO 1.21 2.32 RD In TPY CO2 0.01 5.82 0.03 FeO 0.00 0.00 H2O 0.90 28.00 74.55297 Al2O3 0.00 0.13 to 2 H2O 1.10 28.00
Fe2O3 6.45 12.37 Wet ore 519.434 RD In TPY O2 1.02 763.31 4.11 Fe 0.00 0.00 TDO SiO2 0.06 36.00 MnO 0.00 0.00 step 1 SiO2 0.08 36.00
CoO 0.02 0.03 Dry ore 342.826 fuel.coal wet 22.685 Cal Dryer! N2 3.37 2.895.28 15.58 CoO 0.01 0.03 54.73 Al2O3 0.02 13.90 FeO 0.00 0.01 Secondary Air Al2O3 0.03 13.90
o
SiO2 20.56 39.40 Ni 6.239.44 fuel.coal dry 16.333 H2O 11.18 14.918.12 80.28 SiO2 18.45 39.25 Fe2O3 0.03 14.80 Fe2O3 0.00 0.00 Temp 25 C Fe2O3 0.03 14.80
CaO 0.19 0.40 Calcine CaO 0.02 12.70 CaF2 0.00 0.00 T/h Nm3/h % Vol CaO 0.03 12.70
CaO 0.19 0.36 SO2 0.000 0.04 0.00
MgO 10.79 22.96 45.56 MgO 0.02 8.60 S 0.00 0.25 Total 2.57 2.183 100.00 MgO 0.02 8.60
MgO 12.05 23.10 Primary Air Excess 1.2 A A
Al2O3 0.91 1.93 TiO2 0.00 0.80 P2O5 0.00 0.01 O2 0.59 447 20.50 TiO2 0.00 0.80
S Cal Kiln!

S
Al2O3 0.99 1.89 P2O5 0.01 0.02 Na2O 0.00 0.70 H CO2 0.00 0.00 N2 1.98 1.724 79.00 Na2O 0.00 0.70 H
P2O5 0.01 0.02 RD In TPY RD In TPY Conditioned Ore RD Dust Cr2O3 0.22 0.47 K2O 0.00 1.70 H2O free 0.00 0.00 H2O 0.01 11 0.50 K2O 0.00 1.70
TiO2 0.00 0.00 P2O5 0.00 0.20 P2O5 0.00 0.20
Cr2O3 0.25 0.47 Con. ore wet 439.546 Dust wet 8.970 448.516 Temp 70
o
C Temp 70
o
C Na2O 0.00 0.00 0.00
Rotary Kiln 0.00
LOI 10.44 20.01 Con. ore dry 338.450 Dust dry 6.907 345.358 T/h % LP T/h % LP K2O 0.00 0.01 Rest 0.02 10.60 Rest 0.02 10.60
H2O 26.88 34.00 Ni 6.114.65 Ni 124.79 6.239 Total 66.90 100.00 64.73 Total 1.37 100.00 1.32 C 0.00 0.00 Total 0.18 100.00 RK Dust Calcine Total 0.22 100.00
o o
LOI 9.34 19.86 Temp 300 C Temp 800 C
Rest 0.23 0.44 Ni yield 98.000 Ni yield 2.000 100 NiO 1.18 2.30 Selisih NiO 0.02 2.30 Selisih
H2O 14.04 23.00 T/h % T/h % LP
%Ni 1.82 NiBal 98.000 NiBal 2.000 Ni 0.00 0.00 2.17 Ni 0.00 0.00 0.04 Rest 0.21 0.44 OFF GAS Total 6.73 100.00 Total 38.75 100.00 37.50
Fe2O3 6.35 12.33 Coal dust Fe2O3 0.13 12.33 Coal dust Temp 300 46.01 NiO 0.16 2.31 INDIRECT RED. IN RK NiO 0.88 2.27 Selisih Clinker
o
Hot Gas Fuel Coal FeO 0.00 0.00 FeO 0.00 0.00 %Ni 1.80666 T/h Nm3/h 6.5731707 Ni 0.03 0.45 NiO to Ni 20 % Ni 0.17 0.45 1.25 Temp 800 C
o o Briquette/Pellet Total 28.36 35.850 2.00 Fe2O3 0.18 2.73 Fe2O3 to FeO 80 % Fe2O3 1.04 2.68 Coal dust T/h %
Temp 400.00 C Temp 28 C Fe 0.00 0.00 Fe 0.00 0.00 o
Temp 28 C CO - 36.00 FeO 0.80 11.87 FeO to Fe 0 % FeO 4.51 11.65 Total 0.08 100.00
T/h Nm3/h % T/h % CoO 0.01 0.03 CoO 0.00 0.03 T/h 0.03416 CO2 2.11 1.170 13.90 Fe 0.00 0.00 Fe 0.00 0.00 NiO 0.00 2.27
Total 4.40 3.668.30 100.00 Total 3.453 SiO2 20.22 39.25 SiO2 0.41 39.25 Total 10.30 100.00 7.73 O2 0.00 - 14.80 CoO 0.00 0.04 CoO 0.01 0.04 Ni 0.00 0.45
CO - - - FC 1.38 39.96 CaO 0.21 0.40 CaO 0.00 0.40 NiO 0.18 2.30 N2 1.98 1.724 12.70 SiO2 3.32 49.39 SiO2 18.79 48.49 Fe2O3 0.00 2.68
Ni 0.03 0.40 SO2 0.00 - 8.60 CaO 0.04 0.57 CaO 0.22 0.56 FeO 0.01 11.65
CO2 0.01 5.82 3.00 VM 0.95 27.44 MgO 11.83 22.96 MgO 0.24 22.96
Fe2O3 0.30 3.93 H2O 24.28 32.956 0.80 MgO 1.94 28.83 S, ore - metal 100% MgO 10.97 28.30 Fe 0.00 0.00
O2 1.02 763.31 12.40 ASH 0.19 5.60 Al2O3 0.99 1.93 Al2O3 0.02 1.93 FeO 0.91 11.81 Al2O3 0.17 2.52 S, red coal - metal 100% Al2O3 0.96 2.48 CoO 0.00 0.04
N2 3.37 2.895.28 74.56 H2O 0.97 28.00 P2O5 0.01 0.02 P2O5 0.00 0.02 Fe 0.00 0.00 P2O5 0.00 0.03 P2O5 0.01 0.03 SiO2 0.04 48.49
H2O 0.00 3.84 9.98 SiO2 0.00 36.00 Cr2O3 0.24 0.47 Cr2O3 0.00 0.47 CoO 0.00 0.04 Refining Slag Cr2O3 0.04 0.60 Entwickelt von: Cr2O3 0.23 0.59 CaO 0.00 0.56
o
SO2 0.00 0.04 0.06 Al2O3 0.00 13.90 TiO2 0.00 0.00 TiO2 0.00 0.00 SiO2 3.64 47.12 Temp 28 C TiO2 0.00 0.01 ZULFIADI ZULHAN TiO2 0.00 0.01 MgO 0.02 28.30
CaO 0.04 0.56 T/h % Na2O 0.00 0.01 Na2O 0.00 0.01 Al2O3 0.00 2.48
Fe2O3 0.00 14.80 Na2O 0.00 0.00 Na2O 0.00 0.00
MgO 2.12 27.45 Total 0.00 0.00 K2O 0.00 0.02 RK In TPY K2O 0.01 0.02 P2O5 0.00 0.03
Total Air CaO 0.00 12.70 K2O 0.00 0.01 K2O 0.00 0.01 Al2O3 0.20 2.60 CaO 0.00 0.00 C 0.00 0.00 Con. ore wet 439.546 C 0.71 1.82 Cr2O3 0.00 0.59
o 0.00 0.03 0.00 0.00 LOI 0.00 0.00 Con. ore dry 338.450 LOI 0.00 0.00 TiO2 0.00 0.01
Temp 28 C MgO 0.00 8.60 C 0.00 0.00 C 0.00 0.00 P2O5 CaF2
A Cr2O3 0.05 0.63 Na2O 0.00 0.00 S 0.01 0.08 Ni 6.114.65 S 0.03 0.08 Na2O 0.00 0.01
T/h Nm3/h % Vol TiO2 0.00 0.80 LOI 10.23 19.86 LOI 0.21 19.86
S TiO2 0.00 0.01 CaC2 0.00 0.00 H2O 0.00 0.00 Ni yield 98.000 H2O 0.00 0.00 K2O 0.00 0.02
Total 0.16 136 100.00 Na2O 0.00 0.70 H2O 15.39 23.00 H2O 0.31 23.00 Na2O 0.00 0.01 CaS 0.00 0.00 Rest 0.04 0.55 NiBal 98.000 Rest 0.21 0.54 C 0.00 1.82
H
O2 0.04 29 21.00 K2O 0.00 1.70 Rest 0.23 0.44 Rest 0.00 0.44 K2O 0.00 0.02 SiO2 0.00 0.00 %Ni 2.2728 %Ni 2.2313404 LOI 0.00 0.00
N2 0.13 108 79.00 P2O5 0.00 0.20 %Ni 1.806661 %Ni 1.806661 C 0.00 0.00 Ni 0.00 0.00 RK In TPY RK Out TPY S 0.00 0.08
LOI 0.19 2.47 Fe 0.00 0.00 Briquet. wet 74.179 Calcine wet 279.052 H2O 0.00 0.00
H2O 0.00 - 0.00 Rest 0.00 0.00 S 0.01 0.09 C 0.00 0.00 Briquet. Dry 55.634 Calcine dry 279.052 Rest 0.00 0.54
0.00 H2O 2.58 25.00 Si 0.00 0.00 Ni 1.225.87 Ni 6.226.60 2.2313404 %Ni 2.23134
Rest 0.04 0.54 P 0.00 0.00 Ni yield 19.647 Ni yield 99.794
%Ni 2.20345 S 0.00 0.00 NiBal 19.647 NiBal 99.794
Cr 0.00 0.00
Entwickelt von: Co 0.00 0.00 RK In TPY RK Out TPY
ZULFIADI ZULHAN Slag ref wet - Clinker wet 576
1700 Slag ref dry
Ni -
- Clinker dry
Ni
576
12.85

Hyuga, FeO~10% Ni yield

NiBal
-
-
Ni yield
NiBal
0.206
0.206

MASS BALANCE: ELECTRIC FURNACE

RK In TPY RK Out TPY
Cal EF!
1650 Red.coal wet 23.111 Dust wet 48.446

Slag liquidus temperature, C

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Codemin, FeO~19%
Red.coal dry

RK In
16.640

TPY
Dust dry
Ni
Ni yield
48.446
1.101.08
17.647

Calcine Clinker
Elect. Paste (kg/Calcine) 1.400536264 69.8998874
1.14 kg/TDO EF OFF GAS EF OFF GAS AFTER CO COMBUSTION
30.372.63 fuel.coal wet
fuel.coal dry
28.304
20.379
NiBal 17.647
Antam, FeO~7%
Temp 800
T/h
C
%
o
Temp 800
T/h
o
C
%
Temp
T/h
1000
Nm3/h
C
o

% Vol
Temp
T/h
700
Nm3/h
o
C
% Vol
1600
Total 38.75 100.00 38.83 Total 0.08 100.00 Total 1.77 1.497 100.00 Total 2.55 9.146 100.00
NiO 0.88 2.27 NiO 0.00 2.27 CO 1.62 1.417 94.70 CO 0.00 - 0.00
Ni 0.17 0.45 Ni 0.00 0.45 Electric CO2 0.14 79 5.30 CO2 2.55 1.417 15.50
Fe2O3
FeO
1.04
4.51
2.68
11.65
Fe2O3
FeO
0.00
0.01
2.68
11.65
Furnace O2
N2
0.00
0.00
0.01
0.00
0.00
0.00
O2
N2
1.063
6.666
11.62
72.88 1550
Fe 0.00 0.00 Fe 0.00 0.00 SO2 0.00
CoO 0.01 0.04 CoO 0.00 0.04 0.05 24 MW 33 MVA H2O 0.00 EF Dust
o
SiO2 18.79 48.49 SiO2 0.04 48.49 24.12 33.00 Temp 1000 C
CaO 0.22 0.56 CaO 0.00 0.56 Crude FeNi EF Slag T/h %
MgO 10.97 28.30 MgO 0.02 28.30 Temp 1500
o
C Temp 1650
o
C Total 0.19 99.92 9543.42 1500
Al2O3 0.96 2.48 Al2O3 0.00 2.48 T/h % T/h % NiO 0.00 2.27
P2O5 0.01 0.03 P2O5 0.00 0.03 Total 3.241 100.18 Total 36.60 91.50 Ni 0.00 0.45
Cr2O3
TiO2
0.23
0.00
0.59
0.01
Cr2O3
TiO2
0.00
0.00
0.59
0.01
Ni
Fe
0.821
2.374
25.32
73.26
NiO
FeO
0.05
2.38
0.14
6.50
0.14
6.50
Fe2O3
FeO
0.01
0.02
2.68
11.65
Vale, FeO~24%
Na2O 0.00 0.01 Na2O 0.00 0.01 C 0.004 0.12 SiO2 18.72 51.15 51.15 Fe 0.00 0.00 1450
K2O 0.01 0.02 K2O 0.00 0.02 Si 0.007 0.20 MgO 10.94 29.88 29.88 CoO 0.00 0.04
C 0.71 1.82 C 0.00 1.82 P 0.004 0.13 CaO 0.21 0.59 0.59 SiO2 0.09 48.49
LOI 0.00 0.00 LOI 0.00 0.00 S 0.019 0.59 Al2O3 0.96 2.61 2.61 CaO 0.00 0.56
S
H2O
0.03
0.00
0.08
0.00
S
H2O
0.00
0.00
0.08
0.00
Cr
Co
0.011
0.008
0.33
0.24
P2O5
Cr2O3
0.00
0.21
0.00
0.58
0.00
0.58
MgO
Al2O3
0.05
0.00
28.30
2.48 1400 Falcondo, FeO~18%
o
Rest 0.21 0.54 Rest 0.00 0.54 Liq. Temp. 1404.1 C TiO2 0.00 0.01 0.01 P2O5 0.00 0.03
%Ni 2.23134 %Ni 2.23134045 Crude FeNi 77.8 t/d Na2O 0.00 0.01 0.01 Cr2O3 0.00 0.59 Component

1.712047 0
Entwickelt von:
ZULFIADI ZULHAN
Ladle size
Tapping/day
25.0
3.1
ton K2O
CoO
0.01
0.00
0.02
0.01
0.02
0.01
TiO2
Na2O
0.00
0.00
0.01
0.01
%
Loma de Niquel, FeO~15% Cerro Matoso, FeO~19%
1.712047
Recycle de-S Slag to EF
1 Ni 5.909 t/y Rest
Viscosity
3.11
0.33 Pa.s
8.50 8.53
36.65 50.6089
K2O
C
0.00
0.00
0.02
1.82
1350
Total
Ni
-
-
0.00
0.00
Liq. Temp.
S/M 1.71
o
C LOI
S
0.00
0.00
0.00
0.08
1.0 1.5 2.0 2.5 3.0 3.5 4.0
Fe - 0.00 %Ni 0.113408 H2O 0.00 0.00
C
Si
-
-
0.00
0.00
EF In
Calcine wet
TPY
279.052
EF In
Clinker wet
TPY
576
EF In
De-S Slag
TPY
-
EF In
Shot reject
TPY
0
Rest 0.00
%Ni
0.54
2.231340446
%SiO2 / %MgO
P - 0.00 Calcine dry 279.052 Clinker dry 576 De-S Slag - Shot reject 0
S - 0.00 Ni 6.226.60 Ni 12.85 Ni - Ni 0.00
Cr
S: Z. Zulhan, 2014/2017
Co
-
-
0.00
0.00
Ni yield
NiBal
99.794
99.794
Ni yield
NiBal
0.206
0.206
Ni yield
NiBal
-
-
Ni yield
NiBal
0.000
0.000 FeO=10% FeO=20% FeO=30%
HC FeNi Shot Reject EF Out TPY EF Out TPY EF Out TPY
Total (t/Ladle) 0.00 100.00 Slag wet 263.535 FeNi wet 23.337 Dust wet 1.398
Ni 0.00 23.46 Slag dry 263.535 FeNi dry 23.337 Dust dry 1.398
Fe 0.00 75.40 Ni 298.87 Ni 5.909.38 Ni 31.20
C
Si
0.00
0.00
0.46
0.13
Ni yield
NiBal
29 Maret 2018
4.790
4.790
Ni yield
NiBal
94.710
94.710
Ni yield
NiBal
0.500
0.500
Zulfiadi Zulhan 15
P 0.00 0.12
S 0.00 0.03
S: FGD Suplai Bijih Nikel dan HPM Nikel, Minerba ESDM, 15 Maret 2018

29 Maret 2018 Zulfiadi Zulhan 16

S: FGD Suplai Bijih Nikel dan HPM Nikel, Minerba ESDM, 15 Maret 2018

29 Maret 2018 Zulfiadi Zulhan 17

S: FGD Suplai Bijih Nikel dan HPM Nikel, Minerba ESDM, 15 Maret 2018

29 Maret 2018 Zulfiadi Zulhan 18

 PT Virtue Dragon Nickel Industry

S: FGD Suplai Bijih Nikel dan HPM Nikel, Minerba ESDM, 15 Maret 2018

29 Maret 2018 Zulfiadi Zulhan 19

Peralatan di Laboratorium Pirometalurgi
Teknik Metalurgi – FTTM ITB

29 Maret 2018 Zulfiadi Zulhan 20

Aktivitas Penelitian di Laboratorium
Pirometalurgi Teknik Metalurgi – FTTM ITB

29 Maret 2018 Zulfiadi Zulhan 21

 Defosforisasi HC FeNi
Proses
Defosforisasi
Sampel Reduktif
FeNi 75g awal 25g
Peleburan

Al
Amplas, gerinda Hasil cetak CaF2 CaC2 Reduktor
(100 mesh) (-7mm)

Pelelehan
Sampel
akhir 35g

Terak
ηP dan Lp

Uji OES Uji SEM EDS

S: Z. Zulhan, M.A. Lahino, D.P. Fadilasari 2017/2018

29 Maret 2018 Zulfiadi Zulhan 22
 Defosforisasi HC FeNi
0.08
0.8

0.06 0.7

0.6
Kadar (%)

Kadar (%)
P awal 0.5
0.04
P akhir P awal
0.4
S awal P akhir
S akhir 0.3 S awal
0.02
0.2 S akhir
0.1
0.00
100/0 95/5 70/30 0.0
Perbandingan CaC2/CaF2 3 4 6
100% % Penambahan CaC2 dan CaF2
80%
60%
60% 50%
ηp

40%
40%

ηp
30%
20% 20%

0% 10%
0% 20% 40% 60% 80% 100% 0%
ηs 0% 20% 40% 60% 80% 100%
ηs
S: Z. Zulhan, M.A. Lahino, D.P. Fadilasari 2017/2018
29 Maret 2018 Zulfiadi Zulhan 23
Utilization of Ferronickel Slag for Magnesium
Metal and Ferroalloys Production
Ferronickel slag contains SiO2, MgO and FeO as main component. Small amount of NiO, CoO,
Cr2O3, Al2O3 and CaO is presence in the slag. Typical slag composition: 0.12%NiO, 0.02% CoO,
8.10% FeO, 52.20% SiO2, 35.69% MgO, 2.03% Al2O3, 1.36% Cr2O3 and 0.38% CaO.

Based on FACTSAGE calculation, magnesium as well as ferroalloy can be produced using

ferronickel slag as raw material. The calculation shows that at 1700°C, 0.1 atm and 20% carbon
addition, for 1 ton ferronickel slag where the chemical composition is given above, 128 kg
liquid metal in the form of ferroalloy, 21 kg liquid slag, 210 kg Mg gas (Mg metal) and 305 kg
SiO gas might be produced. The separation of Mg gas and SiO gas shall be studied.

The liquid metal has following chemical composition: 48.7%Fe, 36.8%Si, 7.2%Cr, 2.68%Al,
2.3%Mg, 0.73%Ni, 0.46%C, 0.121%Co.

FACTSAGE calculates under ideal condition and at equilibrium. The experiment shall be carried
out in tube vacuum furnace using graphite crucible under vacuum environment in order to
study the possibility for extraction of magnesium metal and ferroalloys from ferronickel slag.

S: Z. Zulhan, 2017

29 Maret 2018 Zulfiadi Zulhan 24

Slag Ferronickel untuk Memproduksi Mg –
logam dan FeSi (Ferroalloys)

Tekanan (vacuum)
belum memadai

Aplikasi di Industri (???) = Slag tapping (1500 – 1600°C) + reduktor (Vacuum)  Mg + FeSi
+ SiO + slag + CO S: Z. Zulhan, N. Agustina 2018
29 Maret 2018 Zulfiadi Zulhan 25
 Water Model: Simulasi Proses O2-lancing di
Ladle

S: Z. Zulhan, I. Rilandez 2016

29 Maret 2018 Zulfiadi Zulhan 26

Water Model: Simulasi Proses O2-lancing di
Ladle

S: Z. Zulhan, I. Rilandez 2016

29 Maret 2018 Zulfiadi Zulhan 27
Characterization
Pyrometallurgy route:
chemical composition (incl.
free moisture and LOI). The
smelting behavior is
dictated by the presence of
refractory oxides (MgO and
SiO2). TheXRD analysis is
conducted to determine the
phases or minerals in the Saprolite nickel ore
ore.
Element Limonite Saprolite
(%) (%)
Ni 1.49 1.82
Fe 48.33 8.65
Co 0.049 0.023
Cr 1.51 0.323
Mg 0.22 13.93
Si 1.10 18.42
Ca 0.006 0.254
Al 3.46 1.00
Mn 0.39 0.181 Saprolite nickel ore + coal
S: Garaudy, E., Zulhan, Z., 2016
29 Maret 2018 Zulfiadi Zulhan 28
 Characterization

1000°C

Limonite nickel ore

1300°C

S: Garaudy, E., Zulhan, Z., 2016 Limonite nickel ore + coal S: Akbar, A.T., Zulhan, Z., 2015
29 Maret 2018 Zulfiadi Zulhan 29
 Reduction of Oxides in Limonite Nickel Ore

15 min 30 min 45 min 60 min

Iron Nickel Carbon

Element Fe Ni Si Cr O C S
Weight % 76.5 2.2 2.2 3.0 2.3 13.1 0.6

FeCr1.9S4
1500
1400
1380
1400
1333 1400°C
Temperature ( C)

1300

1200 1200

1100 FeCr2.4S4.3
1067
1000
1000

900 1380°C
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Time (minutes)
S: Zulhan, Z., Gibranata, I., 2016

29 Maret 2018 Zulfiadi Zulhan 30

Reduction of Oxides in Saprolite Nickel Ore

100

Ni recovery (%)
80
60
40 30 minutes
20 45 minutes
60 minutes
0
0 5 10
%X
S: Novwizar, R., Zulhan, Z., 2015

S: Hanan, I.A., Zulhan, Z., 2016

29 Maret 2018 Zulfiadi Zulhan 31
 Baja Tahan Karat (Stainless Steel)
20
Stainless and Heat Resisting Steel

18

16
Production (mio. ton)

14

12

10

0
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

Americas EU - Africa Asia w/o China China CEE

http://www.worldstainless.org/

Produksi baja tahan karat di China meningkat dari 0,73 juta ton pada tahun
2001 menjadi 18,98 juta ton pada tahun 2013.

29 Maret 2018 Zulfiadi Zulhan 32

Pertumbuhan dan Proyeksi Pertumbuhan
Produksi Baja Tahan Karat di Dunia

Pariser, G.C., Global Stainless Markets – Where Are They Heading For? 10th
China Nickel Conference, Shanghai, 15-16 March 2013

Laju pertumbuhan produksi

logam 1980-2013
29 Maret 2018 Zulfiadi Zulhan 33
 Penggunaan Baja Tahan Karat dan Produksi
Berdasarkan Grade

1.outokumpu.com/business/stainless-steel-market-review

52% seri 300, 25% seri 400, 20% seri 200

http://www.worldstainless.org/

80% Flat Product,

20% Long Product

http://www.worldstainless.org/

29 Maret 2018 Zulfiadi Zulhan 34

 Baja Tahan Karat (Stainless Steel)

Perbandingan konsumsi baja tahan karat per kapita di beberapa

Hubungan antara GDP dengan konsumsi baja tahan karat per
negara pada tahun 2000, 2005, 2010 (kg/kapita)
kapita pada tahun 2010
http://www.worldstainless.org/

konsumsi baja tahan karat Indonesia adalah sekitar 0,3 kg / kapita pada tahun 2000, 0,9 kg /
kapita pada tahun 2005 dan 1,5 kg / kapita pada tahun 2010.
Dengan menggunakan data jumlah penduduk Indonesia pada tahun 2010 sekitar 237 juta jiwa
maka perhitungan konsumsi baja tahan Indonesia pada tahun 2010 adalah 355,5 ribu ton.

29 Maret 2018 Zulfiadi Zulhan 35

 Proyeksi kebutuhan baja tahan karat
Indonesia hingga tahun 2020
400
Proyeksi Kebutuhan Baja Tahan Karat

300
(Ribu Ton)

200

100

0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Aktual 67.4 62.2 74.8 53.3 90.0 106. 76.0 100. 229. 206. 233. 254. 211.
Proyeksi 211. 258. 276. 293. 311. 328. 346. 363. 381.

PT LAPI ITB, 2015

29 Maret 2018 Zulfiadi Zulhan 36

 Harga baja tahan karat seri 300 dan 400
rata-rata di dunia serta harga nikel
6000 20000
Drawn Bar (316)
5500 18000
Hot Rolled Plate (316)
Stainless Steel Price (USD/ton)

16000
5000

Nickel Price (USD/ton)

Cold Rolled Coil (316)
14000
4500
12000 Hot Rolled Coil (316)
4000
10000 Drawn Bar (304)
3500
8000 Hot Rolled Plate (304)
3000
6000
Cold Rolled Coil (304)
2500
4000
Hot Rolled Coil (304)
2000 2000
Cold Rolled Coil (430)
1500 0
Nickel

http://www.meps.co.uk/
http://www.indexmundi.com/commodities/?commodity=nickel&months=300
PT LAPI ITB, 2015

29 Maret 2018 Zulfiadi Zulhan 37

 Harga baja tahan karat austenik terhadap
harga nikel
10000 55000

Allegheny Ludlum (AISI 304), Surcharge

9000 Allegheny Ludlum (AISI 316), Surcharge
Allegheny Distributor (AISI 304), Surcharge
45000
8000 Allegheny Distributor (AISI 316), Surcharge
Nickel

7000
Stainless Steel (USD/ton)

35000

Nickel Price (USD/ton)

6000

5000 25000

4000

15000
3000

2000
5000

1000

0 -5000
Jun 07
Jun 06

Jun 08

Jun 09

Jun 10

Jun 11

Jun 12

Jun 13

Jun 14
Sep 09
Mar 06

Dec 2006
Mar 2007

Dec 2007
Mar 2008

Dec 2008
Mar 2009

Dec 2009
Mar 2010

Dec 2010
Mar 2011

Dec 2011
Mar 2012

Dec 2012
Mar 2013

Dec 2013
Mar 2014

Dec 2014
Sep 06

Sep 07

Sep 08

Sep 10

Sep 11

Sep 12

Sep 13

Sep 14

Mar 15
PT LAPI ITB, 2015

29 Maret 2018 Zulfiadi Zulhan 38

 Jalur Proses Pembuatan Baja Tahan Karat
Scrap
O2 , N2, Ar DUPLEX - ROUTE
FeCrHC
FeNi
O2 Ar

Hot Strip Mill Cold Rolling Mill

N2/ Ar O2, N2, Ar

EAF Ladle Stirring or

AOD CCM
Ladle Furnace

Duplex: EAF – AOD

O2
Scrap
FeCrHC
FeNi
O2

Ar
N2/ Ar Hot Strip Mill Cold Rolling Mill
EAF Twin VOD CCM

Duplex: EAF – VOD

Scrap
FeCrHC O2 , N2, Ar
FeNi
O2
O2

O2, N2, Ar
Hot Strip Mill Cold Rolling Mill
N2/ Ar
TRIPLEX - ROUTE
EAF AOD
CCM
Ar

Twin VOD
Triplex: EAF – VOD
29 Maret 2018 Zulfiadi Zulhan 39
 Jalur Proses Produksi Baja Tahan Karat
(PT Antam)
10t FeCrHC
0,45t FeMnLC
Fine alloying:
0,60t FeSiMnLC
...t FeNiLC
0,685t FeSi
...t FeMnLC
6,0t Lime
... t FeSiLC
3,4t FeNiLC 1,0t Dolo
...t FeCrLC
17,4t FeCrMC 0,9t CaF2

HRC

3 x 25t IF Ladle
90t AOD 90t LF Hot Strip Mill
CCM

Cold Rolling Mill

Slab
41,8t NPI 20,5t FeNiLC

CRC
2 x 450 m3 BF 3 x RD - 4 x RK - 3 x SAF - DeS - LD Converter

S: Pra FS, 2015

29 Maret 2018 Zulfiadi Zulhan 40
 PT.SMI

S: FGD Suplai Bijih Nikel dan HPM Nikel, Minerba ESDM, 15 Maret 2018

29 Maret 2018 Zulfiadi Zulhan 41