TEKNOLOGI

PENGOLAHAN MINERAL
2 SKS

Course - 4 :
Iron Making

Asful Hariyadi, S.T., M.Eng

www.linkedin.com/in/asfulhariyadi/

hariyadiasful@gmail.com che.itk.ac.id
 Perkembangan Industri Besi/Baja
Konsumsi besi dan baja di seluruh dunia telah dianggap
sebagai barometer pertumbuhan ekonomi dan indikator
kemakmuran masing-masing negara.

IRON MAKING
PERTAMBAHAN JUMLAH PENDUDUK : PERUBAHAN POLA KONSUMSI
KEBUTUHAN BAJA
BAJA MENINGKAT SECARA SIGNIFIKAN

UU MINERBA No. 4 Th. 2009

Kewajiban para pelaku usaha
membangun smelter dan larangan
ekspor bahan baku mentah
namun . . .
Industri Besi dan
Baja menghadapi
Tantangan Serius
 Kominusi Batuan
World energy consumption

▪ World economic growth required highly steel based material

▪ Consumes around 5% of the total world energy[=24 EJ]

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Iron Making Industry Why it is importan

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FEED
PREPARATION
What is Comminution?

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Kokas
Metallurgi
Kokas merupakan bahan dengan karbon tinggi
dan memiliki kadar polutan rendah. Jenis bahan
bakar ini merupakan hasil dari pengolahan
batubara yang memiliki tingkat kalori tinggi
dengan memanaskannya tanpa udara.
Kokas
Metallurgi
 Fuels Why it is important?

▪ The mainly is fossil fuels and non-renewable

▪ Limited amount
▪ Expensive
▪ CO2 emission: 1519 kg-CO2/ton-pig iron
7] Guo et.al. Energy 35 (2010) 4356–4360.; [2] The Japan Iron and Steel federation.

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Raw Material: Iron Ore

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Blast Furnace – Feed Preparation

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Blast Furnace – Feed Preparation

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 Blast Furnace – Feed Preparation
Agglomeration of Iron Ore Fines basically involves two main methods
1. Sintering
2. Pelletising
Sintering is the agglomeration technique of Iron Ore Fines in the size rage of -
10+0.15 mm to produce clusters by incipient fusion at high temperature.
Pelletisation is the other mode of agglomeration applicable for fines below
325 mesh size. Sinter Ore

1% replacement of calibrated lump by Sinter or Pellet reduces the Coke rate by

1.5Kg/T of hot metal produced

20 to 70% Sinter can be used successfully in Blast Furnace

Use of Pellet gives rise to improved permeability compared to Lump Ore or Sinter

15 to 20% of pellets are used in many furnaces along with lump ore & sinter Pellet Ore

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Blast Furnace – Feed Preparation

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Blast Furnace – Feed Preparation

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Blast Furnace – Feed Preparation

Komposisi

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Blast Furnace – Feed Preparation

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Blast Furnace – Feed Preparation

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Feed Preparation – Sintering Ore

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Feed Preparation – Sintering Ore

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Feed Preparation – Sintering Ore

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Feed Preparation – Sintering Ore

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 Feed Preparation – Sintering Ore
2Fe2O3
Heating Heating Cooling
Single
lump
Sinter Product
2Fe2O3

+ CaO 2Fe2O3CaO at 12000C

CALCIUM FERRITE
2Fe2O3.CaO + Al2O3.SiO2 2Fe2O3 CaO.Al2O3.SiO2
2Fe2O 3 (SFCA)
2Fe2O 3
SILICO FERRITE OF CALCIUM AND
ALUMINIUM
MgO Al2O3 SiO2 CaO Fe2O3 MnO Mineral
0.0 0.3 0.4 0.3 99.0 0.0 Hematite
3.3 1.2 1.6 4.7 88.0 1.2 Magnetite

SLAG BOND 2.9 1.6 5.1 8.4 80.9 1.2 SFCA

2Fe2O3
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PROCESS
MANUFACTURING
 Iron and steel production

Finishing process

Iron & Steel

Production
Raw materials:
Non-renewable resources
High grade coal = 690 kg/ton-pig iron
Limited amount
High rank iron ore = 1390 kg/ton-pig iron
Expensive
Limestone = 140 kg/ton-pig iron

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▪ Blast Furnace (BF) – Basic Oxygen Furnace (BOF)
▪ Direct Reduction (DR) – Electric Arc Furnace (EAF)
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Steel production route 1 : BF-BOF
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 20

Blast Furnace operation

BF gas
Solid
flowing Reactions:
Iron ore 200oC 3Fe2O3 + CO → 2Fe3O4 + CO2 ;
Fe3O4 + CO → 3FeO + CO2
Coke (C) 500oC 2CO → C + CO 2
FeO + CO → Fe + CO 2
900oC
FeO + CO → Fe + CO2
1200oC FeO + C → Fe + CO
C + CO2 → 2CO

C + CO2 →2CO
1700oC
C + O2 → CO2

❑ Indirect reduction is main reaction to produce pig iron (Fe)

❑ Huge consuming of coke and high temperature operation
❑ Excessive CO2 generation

[9] http://webs.purduecal.edu/civs/research/educationtraining/virtual-blast-furnace/; [10] http://www.panoramio.com/photo/72496591

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Mass Balance in Pig-Iron

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Kompartemen Blast-Furnace

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Slag Formation

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 Blast Oxygen Furnace
▪ Blowing of oxygen instead of air unlike the
Bessemer’s process.
▪ Pretreatment process to remove sulphur,
phosphorous and silicon.
▪ Heat needed for the process is generated by the
process itself.
▪ Composition of molten steel produced contains
0.4% carbon, 0.075% manganese, 0.03% silicon,
and negligible traces of sulphur, phosphorous.
▪ Alloying takes place to provide steel with the
required properties.

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Blast Oxygen Furnace

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 Blast Oxygen Furnace
STEEL
▪ Diffuse Necking – strength retained during
necking gives additional safety.
▪ High Modulus Elasticity – easy to form shapes
as less spring back.
▪ Uniform Strain deformation.
▪ Have high Fatigue strength.
▪ Easy for welding processes.
▪ After the Bake-hardening process greater strain
hardening is achieved.
▪ Lower tooling costs.
▪ Steel gives better resistivity to surface
damage in material handling.
ALUMINIUM
▪ Localized Necking – fracture occurs after uniform
elongation.
▪ Low Modulus Elasticity – greater amount of elastic
strain leads to difficulty in forming.
▪ Non-uniform strain deformation resulting in strain
concentration.
▪ Have low Fatigue strength.
▪ Unable to withstand high dynamic loads –difficulty in
welding.
▪ The rate of increase in strain hardening is less than steel.
▪ Higher tooling costs.
▪ Less resistivity due to lower hardness and Yield
strength.
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Blast-Oxygen
Furnace
Steel production route 2 : DR-EAF
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Blast-Oxygen
Furnace
THANK YOU