1.

Faizah Ali
02511740000095
2. Muhammad Afdhel
Refialdi
02511740000107
3. Samuel Areliano P.S
02511740000110
 ABSTRACT

Ore processing through the extraction process is classified into several methods, among
others: Pyrometallurgy, Hydrometallurgy, and Electrometallurgy. Among the three methods,
the extraction process through the pyrometallurgical method is the most widely used process
compared to hydrometallurgy and electrometallurgy. Before the ore is fed to the
pyrometallurgy reactor / furnace, the ore will be crushed and agglomerated. This
agglomeration process aims to agglomerate and homogenize the size of the ore so that it is
good to be processed in the furnace. The agglomeration process is a process of preparing ore
before it is put into the smelter so that materials are suitable and acceptable to be processed in
the smelter in terms of shape, strength, reduction, permeability, chemical properties that affect
the process in BF (i.e: base / acidity). The agglomeration process itself consists of three
stages, namely: sintering, palletizing and briquetting. In this experiment will study about
carbothermic direct reduction of two kind of metal, which are Nickel and Iron. The purpose of
this experiment is to conduct direct Nickel Ore reduction process to increase the Nickel and
Fe content. To begin this experiment we need few materials such as, ore, additive, binder,
coal, limestone and LPG. The first step that we have to do is crushing the ore with the cursher
and sieve it using 50 mesh. Then the lateritic nicel ores mixed with the additive. After tha take
some tapioca and mix it in 100 mL of water and heat them in boiling water until slightly
thickened. The mixture of ore and additive were added with tapioca which has slightly
thickened and stirred until evenly distributed. And then formet the briquette using a mold with
pillow shape and compactin device with a pressure of 30 kgf / cm2. The dry them in 110o C for
3 hours using oven. The briquette is inserted into the crucible which contains a mixture of
coal and limestone. The we move to the next step Crucible is placed in Muffle Furnace and
preheated to 7000C in 60 minutes. Then, it was holded at temperature 700 o C for 2 hours
Crucible is placed in Muffle Furnace and preheated to 700 o C in 60 minutes. Then, it was
holded at temperature 7000C for 2 hours. The temperature was increased to temperature of
1400oC in 60 minutes. Then, it was holded at a temperature of 1400o C. Then the briquette is
cooled inside the muffle furnace for 12 hurs and removed from muffle furnace. Then calculate
it. After we calculate it using standart formula we get the nickel recovery addition with 7%
sulphur ijen is 98% and Iron recovery with addition 7% sulphur ijen is 60 %. And for the
grade we get 16.2%

Keywords : Nickel, Lateritic, Limestone, Selective Reduction Ores

 TABLE OF CONTENT
ABSTRACT................................................................................................................................2
TABLE OF CONTENT..............................................................................................................3
LIST OF FIGURE.......................................................................................................................4
LIST OF CONTENT..................................................................................................................5
CHAPTER I................................................................................................................................6
I.1 Background of the Experiment....................................................................................6
I.2 Formulation of the Problem.........................................................................................6
I.3 Purpose of the Experiment...........................................................................................6
CHAPTER II...............................................................................................................................8
II.1 Nickel...........................................................................................................................8
II.2 Nickel Ore and the extraction process..........................................................................8
II.3 Nickel Laterit Limonitic.............................................................................................10
II.4 Coal............................................................................................................................12
II.5 Limestone...................................................................................................................13
II.6 Selective Reduction of Ores.......................................................................................14
II.7 Thermodynamics Direct Reduction of Limonite / Iron Laterite Nickel.....................14
CHAPTER III...........................................................................................................................18
III.1 Flow Sheet Diagram.....................................................................................................18
III.2 Materials.......................................................................................................................19
III.3 Equipment.....................................................................................................................19
III.4 Experiment Procedures.................................................................................................19
CHAPTER IV...........................................................................................................................21
IV. 1 Data Analysis...............................................................................................................21
IV.2 Discussion.....................................................................................................................22
CHAPTER V............................................................................................................................24
V.I Conclusion.................................................................................................................24
V.2 Suggestion..................................................................................................................24
BIBLIOGRAPHY.....................................................................................................................25
 LIST OF FIGURE

Figure 2. 1 Typical weathering profiles for nickel laterite ores)………………………………9

Figure 2. 2 Extraction of nickel and ferro-nickel from laterite and sulfide ores......................10
Figure 2. 3 Sub-bituminous coal..............................................................................................13
Figure 2. 4 Depositional of Limestone.....................................................................................13
Figure 2. 5 Classification of Limestone...................................................................................14
Figure 2. 6 Ellingham Diagram.............................................................................................15Y
Figure 3. 1 Flow Diagram..........................................................................................................1
Figure 4. 1 Graph of XRD concentrate product reduction on the various varieties of sulfur..23

LIST OF TABLE
Table 2. 1 Composition of Laterite......................................................................................10Y
Table 4. 1 Mass and Recovery of Nickel and Iron..................................................................20
Table 4. 2 Nickel Grade..........................................................................................................21
 CHAPTER I
INTRODUCTION

I.1 Background of the Experiment

Ore processing through the extraction process is classified into several methods, among
others: Pyrometallurgy, Hydrometallurgy, and Electrometallurgy. Among the three methods,
the extraction process through the pyrometallurgical method is the most widely used process
compared to hydrometallurgy and electrometallurgy. Before the ore is fed to the
pyrometallurgy reactor / furnace, the ore will be crushed and agglomerated. This
agglomeration process aims to agglomerate and homogenize the size of the ore so that it is
good to be processed in the furnace.
The agglomeration process is a process of preparing ore before it is put into the smelter so
that materials are suitable and acceptable to be processed in the smelter in terms of shape,
strength, reduction, permeability, chemical properties that affect the process in BF (i.e: base /
acidity). The agglomeration process itself consists of three stages, namely: sintering,
palletizing and briquetting.
In this experiment will study about carbothermic direct reduction of two kind of metal,
which are Nickel and Iron. And this grup will do the reduction ore process about nickel.
Nickel ore is generally divided into two classes based on the type of impurity, i.e. nickel
sulfide ore and lateritic nickel ore (oxide). The availability of nickel ore in the world is
divided into 60% of sulfide ore and 40% of lateritic ore, but nickel ore processing in the world
is dominated by nickel sulfide ore processing which reaches about 70%. Indonesia itself is
rich in nickel ore oxide resources. At this time, laboratory will be done process of reduction of
nickel laterite ore of lateritic nickel ore type by pyrometallurgy process using muffle furnace.
This reduction process aims to separate the nickel content from its impurities.

I.2 Formulation of the Problem

Formulation of the problem in direct reduction process is how to conduct direct Nickel
Ore reduction process to increase the Nickel and Fe content.

I.3 Purpose of the Experiment

The purpose of direct reduction process experiment is to conduct direct Nickel Ore
reduction process to increase the Nickel and Fe content.
 CHAPTER II
LITERATURE FREVIEW

II.1 Nickel
Nickel is one of the most important and important metals has many applications in
industry. There are many types of products nickel such as fine metals, powders, sponges, and
others. 62% of nickel metal is used in stainless steel, 13% is consumed as superalloys and
non-metal alloys because of their properties corrosion resistance and high temperature
resistance (Astuti, et al., 2012). The large number of nickel applications is due to the special
properties of nickel, namely having resistance to corrosion attack, good strength and
toughness at high temperatures, and has relatively low thermal and electrical conductivity
(INSG, 2008).
In Indonesia, nickel resource potential is known reached 1,878,550,000 tonnes with an
average nickel content of 1.45%. Some of the potential resources are already mined and
exported in the form of nickel matte, ferronickel or nickel ore without going through
processing and refinement by many companies growing in the last decade. Latest data from
the Agency The geology of the Ministry of Energy and Mineral Resources shows that
Indonesia has nickel resources of 2,633 million tonnes of ore with nickel reserves of 577
million tonnes of ore scattered across Sulawesi, Kalimantan, Maluku and Papua (ESDM,
2012).
As we know, nickel ore is classified into two, namely sulfides and laterites. Types of
sulfides formed thousands of meters below the earth's surface by the reaction of sulfur with
rocks containing nickel with a grade between 0.5-8.0% Ni. While the type of laterite formed
over a long time as the results of weathering rocks that contain nickel and produce nickel
which is deposited again on the formation of oxides or silicates with levels of 1.0-2.0% Ni
(Kirk, 1998).
In some of the current research, it can be said that laterite nickel will dominate nickel
production in the near future in the future. Laterite nickel will dominate nickel production due
to its availability. Existing nickel reserves in the world, 36% is sulfide and 64% is laterite.
Total more laterite ore than sulfide ore. The reason for domination Other nickel laterite
production is due to its mining costs lower than the mining of sulfide ores rests on hard rock.
Furthermore, in terms of the effect on environment, nickel production from sulfide ore poses a
problem in the environment, namely the creation of sulfur oxide emissions. While the
production of nickel based laterite ore has environmental problems less. And seen from the
technological factor, there are ways that can be making laterite-based nickel production more
process profitable through reduced production costs and increase in revenue by product. So as
to make production laterite-based nickel is more economical and competitive (Shoubao Li,
1999).

II.2 Nickel Ore and the extraction process

Nickel ore is classified into two, namely sulfides and laterites. Types of sulfides
formed thousands of meters below the earth's surface by the reaction of sulfur with rocks
containing nickel with a grade between 0.5-8.0% Ni (Kirk, 1998). Sulfide ores are typically
derived from volcanic or hydrothermal processes and usually include copper (Cu) and/or
cobalt (Co), and often precious metals such as gold (Au) or platinum (Pt), palladium (Pd) and
rhodium (Rh) (the platinum group metals or PGMs (Mudd, 2010). While the type of laterite
formed over a long time as the results of weathering rocks that contain nickel and produce
nickel which is deposited again on the formation of oxides or silicates with levels of 1.0-2.0%
Ni (Kirk, 1998). Laterite ores are formed near the surface following extensive weathering of
ultramafic rocks, and occur abundantly in tropical climates around the equator, the arid
regions of central Western Australia or humid areas of Eastern Europe. The weathering leads
to distinct ore types, namely, limonite, nontronite and saprolite/garnierite/serpentine, with
different impurity levels of magnesium, iron and silica, as well as a transition zone between
the ore types (Mudd, 2010). This is the figure of typical laterite profile:

Figure 2. Typical weathering profiles for nickel laterite ores (adapted from Dalvi et al., 2004;
Wedderburn, 2009)
Historically, most of the Ni production has come from sulfide ores with laterite ore
which only provides a modest source. In the term known Ni Resources, about 60% is found in
laterites while 40% is found to be contained in sulfides. That is the main reason for this is the
difficulty of processing Ni laterites. Compared to sulfide laterite ores, it requires a large
amount and complex treatment to extract Ni, and has historically been more expensive than
sulfide ores (Mudd, 2010).
As we know, Ni production from sulfide ore involves open cut or underground
mining, followed by concentration via flotation, smelting of the concentrate to produce matte
Ni (± Cu), then refining it to produce pure metal. This is common in mines, smelters, and
refineries in different locations, depending on the geographic factors of the area. As we know,
the production of Ni from sulfide ore involves open pit or underground mining, followed by
concentration through flotation, smelting the concentrate to produce Ni matte (± Cu), then
refining it to produce pure metal. This is common in mines, smelters, and refineries at
different locations, depending on the geographic factors of the area (Mudd, 20120). On the
other hand, Ni production from laterite ore is relatively complex. The processing of laterite
nickel ore is divided into two namely pyrometallurgical and hydrometallurgical processing.
The selection of the process to be used is determined by ore content, limited increase in
content, complex processing technology, geographic conditions, as well pay attention to
infrastructure needs such as power plants, ports, and slag processing facilities (Filipe Manuel
R, 2013). Pyrometallurgical processing is generally only can produce nickel with a grade of
1.50%, meanwhile on average the world's laterite nickel content is about 1.45% so that
processing pyrometallurgy is conventionally ineffective (Mayangsari, Prasetyo, 2016).
Laterite processing hydrometallurgy with ammonia leaching or HPL (high pressure leaching)
with sulfuric acid was initially thought to be effective in increased levels of Ni. However,
after further investigation, the process Leaching can cause environmental and health problems
and can increase production costs (Mayangsari, Prasetyo, 2016). So, this is the sceme for
extraction of nickel and ferro-nickel from laterite and sulfide ores:

Figure 2. Extraction of nickel and ferro-nickel from laterite and sulfide ores (Crundwell, et
al., 2011)
II.3 Nickel Laterit Limonitic
Nickel laterites are formed by the intense weathering of ultramafic rocks exposed in
tropical to sub-tropical climates. They account for 40% of annual global nickel production
and contain 60% of the world’s total landbased nickel resources (Kuck 2008). During the
weathering process, nickel-bearing minerals, olivine and serpentine, are destroyed in an
oxidizing environment producing iron oxide deposits containing residual concentrations of Ni.
Nickel laterites are the product of lateritisation of Mg-rich or ultramafic rocks which have