TEKNOLOGI IRON

MAKING
Oleh:
Maulud Hidayat

Flow proses bijih besi menjadi pig

iron dan DRI (iron making)
Mining
Gas alam / batu bara

Iron
Ore

As lump ore

DRI

DR Proses
HYL, SL/RN

Crushing/
Grinding

Smelter

Pig iron

Pelletizing/
Benefi
ciation

Sintering
Kokas

As fine ore

Batu bara

Blast
Furnace

pig iron

Direct
Smelting
Process

pig iron

Teknologi untuk memproses bijih

besi menjadi pig iron atau DRI
Fines Ore

Natural
Gas

Coal

Coking
Coal

Agglomerated Ore

Commercial

Pilot/Demonstration

Commercial

Pilot/Demonstration

Circored
FIOR
Finmet
Iron Carbide

Procedyne
Qualitech
Spirex

Midrex
HYLSA
Zam-zam

AREX, Purofer,
Ghaem, ITMk3,
Danarex

AISI, DIOS, Comet,

AusIron/Ausmelt,
Circofer, CCF,
Hismelt (semi)
Finex, Plasmared,
Romelt , Cleansmelt

COREX

ACCAR/OSIL, DRC,
DryIron, Inmetco,
Fastmet/Fasmelt
Iron Dynamic, MauMee,
Kinglor-Metor, SL/RN,
Krupp-CODIR,
Redsmelt, Tecnored

Blast
Furnace

Direct reduction processes

No

ITEM

MIDREX

HYL III-ZR

SL / RN

Circored

IRON-CBD

Zam-zam

FINMET

Pellet,
lump

Pellet,
lump

Lump, iron
sand

Fines

Fines

Pellet,
lump

Fines

1.

Raw material

2.

Gas preparation
- Type of equipment
- Temperature, OC
- Pressure, kg/cm2

Reformer
925- 950
1.5 2.0

In situ
830
7

Reformer
850 - 900
-

Reformer
NA
NA

Reformer
830
-

Reduction reactor
- Type
Temp., OC
Pressure, kg/cm2

Shaft fnc
760- 925
-

Shaft fnc
930
45

Rotary kiln
9001100
1 15

Fluid bed
630 - 850
4,0

Fluid bed
600
1.8

Shaft fnc
850-1450
45

Fluid bed
550- 800
11 - 13

Consumption rate
- Natural Gas /coal
- Oxygen
- Water (M3 )
- Electricity (kwh)

10,92 GJ
1,5
110

9,24 GJ
55 NCMH
0,9
110

Coal 0.75 t
2,5
70

11,34 GJ
1,5
100

13 GJ
1,3
190

9,99 GJ
1.5
110

12.6 GJ
2.5
150

5.

Product
- % mtz
- % tot-C

DRI/HBI
92 95
0.7 2

DRI/HBI
90 94
1.5 2.2

DRI
92 93
34

HBI
93
2

Fines
94
6.5

DRI/HBI
92 min
1.2 min

HBI
91 - 93
0.5 - 3

6.

Plant capacity, tpy

1.2 m

675,000

3-500,000

500,000

330,000

800,000

500,000

7.

Population (mod)

50

18

17

3.

4.

Direct Smelting Processes

1

Status technology

Smelting Furnace

Corex

Ausiron

Hismelt

Romelt

DIOS

commercial

demo plant

under const

Demo plant

pilot plant

a. pre reduction

available

un available

available

un available

available

b. pressure

4 - 5 bar

(-75) - (-150) Pa

1.5 - 1.8 bar

sub atm.

3 - 4 bar

c. temperature

850 - 1450

< 1800

800 - 1600

< 1750

800 - 1700

1450 - 1500

1574

1480

1960

1480

( 62% Fe )

( 61% Fe )

( 62% Fe )

( 52% Fe )

( 62% Fe )

b. coal (kg/tprod)

1000 - 1100

910 - 1030

620 - 680

700 - 860

800

c. flux (kg/tprod)

200 - 500

163

78

23

150

a. Oxygen

550 - 650

1350

550

950 - 1092

594

b. Natural gas

Na

20

17

Na

c. Air

1030 - 1180

2420

200 - 245 kg

Na

Post comb. Ratio

40%

85% - 100%

40% - 60%

70%

45%

Heat Transfer Eff.

85%

65%

95%

60% - 80%

90%

Feeding
a. iron ore (kg/tprod)

Gas

Alternative Ironmaking
Technologies

The MIDREX Process

MIDREX is the most popular process currently in use. It utilises iron ore
pellets in a shaft with counter current flow of reducing gases. The reducing
gas is produced by catalytic breakdown of natural gas to H2 and CO.
Reducing gas is preheated to improve the reformer thermal efficiency.
The HYL Process
HYL III is the second most popular process currently in use. It utilises iron
ore pellets, and natural gas, in a shaft with counter current flow of reducing
gases. The method used for reducing gas handling and reforming is the
main difference to the MIDREX process.
The SL/RN Process
SL/RN is the principal process in use for coal based DRI production. A large
quantity export gas (mainly CO) is produced, which must be used for cogeneration of electric power in order to make the process energy efficient.
Coal selection is important to avoid producing DRI that is high in sulphur.

Alternative Ironmaking
Technologies

The Corex Process

Corex is the principal alternative process to the blast furnace for producing
liquid iron. It requires co-generation of electric power using by-product
gases to achieve satisfactory process economics. Lump ore and coal are
reacted in a two stage process.
The FINMET Process
FINMET is the process employed by BHP at Port Hedland to produce HBI.
It is the only commercial production method capable of using the more
easily obtainable iron ore fines. Iron ore is progressively reduced in a series
of four reactors with counter current flow of reducing gas. Reducing gas is
made by processing natural gas through a steam reformer.
The Romelt Process
A Romelt plant has operated at demonstration scale for several years. Iron
ore and waste iron oxides are reacted with coal in a horizontal smelting
furnace to produce liquid iron. As with other coal intensive processes, cogeneration of electric power should be considered to improve the overall
economics.

Alternative Ironmaking
Technologies
The Circored Process
Circored is a new process, and the first commercial plant was
commissioned in 1999. Iron ore fines are reacted in a two stage
fluidised bed reactor, with hydrogen produced from natural gas.
The FASTMET Process
FASTMET is a new process, still being developed. "Self-reducing"
green pellets consisting of iron ore fines and pulverised coal are
reduced on a rotary hearth furnace. Liquid iron can be produced
under appropriate conditions.
The COMET Process
Comet is a new process, still being developed. Alternative layers of
crushed coal and iron ore or fines are placed on a bed in a rotary
hearth furnace. Lime is added to help fix sulphur from the coal.

Alternative Ironmaking
Technologies

The Tecnored Process

Tecnored is a new process, with the first commercial plant under construction. Charge material
consists of iron ore and/or low grade iron oxide residues in the form of green pellets. The raw
materials are reacted in a low shaft furnace with hot blast, to produce liquid iron.
The Circofer Process
Circofer is a new process, still under development. It uses iron ore fines and pulverised coal in a
two stage fluidised bed reactor.
The Redsmelt Process
The INMETCOTM Process has operated at demonstration scale for many years. A version of this
technology (Iron Dynamics Inc.) commenced commercial operation in 1999. Self-reducing green
pellets of iron ore fines or waste oxides in combination with crushed coal are charged to a rotary
hearth furnace and progressively reduced. The DRI process in combination with a submerged arc
furnace for hot metal production has been renamed as REDSMELT.
Iron Carbide Process
The commercial production of iron carbide is a relatively new process, with only two plants
constructed, the first of which was closed down in 1999 after operating for 3 years. Very fine iron
ore is reduced with reducing gases in a fluidised bed reactor. The second plant employs two
reactors, and it is hoped that this will overcome the productivity and quality problems suffered by
the first plant.

Blast Furnace
(Indirect Reduction)

PENDAHULUAN
INDUSTRI BESI DAN BAJA DIBAGI DALAM 2 KELOMPOK BESAR:
WROUGHT PRODUCT:
WROUGHT PRODUCT ADALAH PRODUK COR YANG MENGALAMI PROSES LANJUT BERUPA
PENGERJAAN MEKANIS SEPERTI ROLLING, EXTRUSI, FORMING, JOINING (WELDING)

CAST PRODUCT:
CAST PRODUCT ATAU PRODUK COR ADALAH PRODUK YANG DIPEROLEH DENGAN CARA
MENUANGKAN LOGAM CAIR KE DALAM CETAKAN DAN BENTUKNYA DIPEROLEH SESUAI
DENGAN BENTUK CETAKANNYA

PENGOLAHAN BESI KASAR

BAHAN BAKU BLAST FURNACE:
BIJIH BESI DALAM BENTUK BONGKAHAN DAN DISEBUT
LUMP ORE
LUMP ORE DIPECAH SEHINGGA UKURANNYA 12 MM SAMPAI 35
MM
KANDUNGAN BESI DALAM LUMP ORE
HEMATITE (FE2O3) ATAU MAGNETITE (FE3O4) BERKISAR ANTARA 50%

SAMPAI DENGAN 70%.

APABILA KURANG DARI ITU,

BESI OKSIDA DIOLAH DULU MENJADI BENTUK PELLET SEHINGGA
KANDUNGAN BESINYA NAIK.

BATU BARA
DIMASUKKAN KE DALAM COKE OVEN DAN DIPANASKAN PADA
TEMPERATUR 13000C.
SEMUA GAS AKAN MENGUAP DAN BATU BARA INI DISEBUT KOKAS.

BATU KAPUR
UNTUK PROSES DI DALAM DAPUR TINGGI MASIH DALAM
BENTUK CACO3.

PABRIK PENDUKUNG BLAST

FURNACE
1. Sintering Plant :
Bijih besi Besi sinter

2. Cooking Plant :
Batu bara Coke (kokas)

3. Calcination Plant :
Batu kapur & dolomit Kapur & dolomit bakar

4. Hot stoves
Pemanas udara

FLOW SINTERING PLANT

Water

Ore, Flux,Coke,
Return fines, Lime

Sinter Machine
ESP

Mashing Stage

Main Fan
Emission
Monitoring
Quench

Fine Scrubbers

Mashing
Water

Sludge
Water
Process Air

Fan
Recycling
Fe-Components

Water

Nat.
Gas
Reheating

Discharge
Water

Water
Treatment

Slag
Immobilisation

Thickener
Sludge Tank
Floating Sludge
to BF

Sludge

Depot
Cleaned Water

PENGOLAHAN BESI KASAR

PENGOLAHAN BESI KASAR

PROSES DI COKE OVEN

Neraca bahan sintering machine

Iron ore
BF-fine
Mill scale

422
35
4

Flue dust
Lime st
Dunite

8
52
13

Base mix
554

Mixing & Reroling drum

829 wet

Dunite
6

Sinter machine
884 wet

22

Sinter Breaker
764 dry

Lime st

Coke brz

Coke brz

20

Sinter Cooler
764 dry

9
Calz.Lime
10

Cascade chute
635 dry
129 dry

Return fine
204

Heart layer screen

388
376
Fine screen
172
204

Water
24

Besi sinter

505 dry

PENGOLAHAN BESI KASAR

PROSES PENGOLAHAN BESI DI BLAST FURNACE:

3 BAHAN BAKU UTAMA DI ANGKAT SECARA KONTINU KE ATAS

DAN
DIMASUKKAN KE DALAM DAPUR TINGGI.

UDARA PANAS YANG DIPANASKAN OLEH GAS BEKAS HASIL PROSES, MELALUI
TUYERE MASUK KE BAGIAN BAWAH DAPUR TINGGI SEHINGGA MEMBAKAR
KOKAS

TIMBUL PANAS YANG TINGGI DAN MENGHASILKAN GAS CO.

DI DALAM SHAFT TERJADI REAKSI CO DENGAN BIJIH BESI MELALUI PERSAMAAN:
>4500C 3Fe2O3
>6000C Fe3O4
> 7000C FeO
FeO

+ CO
+ CO
+ CO
+C

2 Fe3O4
3 FeO
Fe
Fe

+ CO2
+ CO2
+ CO2
+ CO

TERJADI DISOSIASI KAPUR:

CaCO3
FeS + CaO

CaO + CO2
+ C CaS + FeO

+ CO

PENGOLAHAN BESI KASAR

BESI YANG TELAH MENCAIR JATUH KE DALAM HEARTH.
BESI CAIR (HOT METAL) INI MEMILIKI KANDUNGAN KARBON SAMPAI
MENCAPAI 4%.
MELALUI SALURAN PEMBUANGAN SLAG DITAMPUNG PADA PENAMPUNG.
BESI CAIR DIALIRKAN MELALUI SALURAN LAIN DITAMPUNG KE DALAM
TORPEDO CAR DAN DIANGKUT KE UNIT PENGOLAHAN BAJA
BESI CAIR DITUANGKAN KE DALAM LADLE

Blast Furnace

Cooking Plant

Blast Furnace & Sinter Plant

Typical Blast Furnace

Kontruksi Blast Furnace

Energi Blast Furnace

Sensor Blast Furnace

Stove & Campain Blast Furnace

Stove Blast Furnace

Blast Furnace Tapping

Hismelt Kninawa Australia

Direct Reduction
Technology
Hyl & Midrex

Midrex & Hyl3

Hitemp Hyl-3

Self Reforming Hyl3

Midrex Technology

Route Midrex Process

Process Description Midrex (1)

Natural gas based process developed by Midland-Ross
Corp. First commercial plant was built in 1969 and at
present is the most widely used process for
manufacturing of DRI.
In the MIDREX process lump ore or iron oxide pellets
are charged into a shaft furnace. Reducing gas injected
into the furnace reduces the feed stock as the iron ore
descends to the bottom of the furnace. The furnace
discharges the DRI after it has cooled down in the lower
half of the shaft. Reducing gas leaves the top of the
furnace, where it is recycled.

Process Description Midrex (2)

The shaft furnace of a standard cold discharge plant has
two independent zones. In the reduction zone, iron oxide
(Fe2O3) is heated and reduced (i.e. the oxygen is
removed) by hot counter flowing reducing gas containing
hydrogen (H2) and carbon monoxide (CO). In the cooling
zone, a counter flowing gas cools the DRI and increases
its carbon content.
Reducing gas is generated from a mixture of natural gas
and recycled gas from the shaft furnace (i.e. top gas).
This mixture is chemically converted to 90-92 percent H2
and CO in a gas-tight, refractory-lined furnace (reformer)
containing alloy tubes filled with catalyst.

Process Description Midrex (3)

Reforming takes place as the gas mixture flows
upward through the catalyst tubes. The hot
reducing gas is used directly in the shaft furnace
to conserve energy.
The thermal efficiency of the reformer is greatly
enhanced by the heat recovery system. This unit
consists of tube bundles located in the reformer
flue gas ducts. Sensible heat is recovered from
the reformer flue gas to preheat both the
combustion air used in the reformer burners and
the mixture of top gas and natural gas fed to the
reformer tubes

Product Characteristics of Midrex

Typical product characteristics of Midrex process
Property
DRI
HBI
Fe Total*

90 - 94%

90 - 94%

Fe Metallic

83 - 89%

83 - 89%

Metallisation

92 - 95%

92 - 95%

Carbon

1.0 - 2.5%

0.8 - 1.2%

P*

0.005 - 0.09% 0.005 - 0.09%

S*

0.001 - 0.03% 0.001 - 0.03%

Gangue*

2.8 - 6.0%

2.8 - 6.0%

Trace

Trace

Bulk Density* (t/m )

1.6 - 1.9

2.4 - 2.8

Apparent Density* (t/m3)

3.4 - 3.6

5.0 - 5.5

Cu, Ni, Cr, Mo, Sn, Pb, and Zn*

3

* Depends on the iron ore source

Direct Smelting Technologies

for aglomerated ore
Corex

Route process- Corex

Process Description- Corex

Coal-based direct smelting reduction process developed by VAI to
produce hot metal. First commercial plant was built in 1989 at Iscor's
Pretoria Works in South Africa.
In the first stage of the process, iron ore in lump, pellet, or sintered
form is reduced in a reduction shaft by process gas in the counter
flow. Process gas is generated in a melter/gasifier which is directly
coupled to the shaft. The feed is reduced to produce approximately
93% metallised DRI, which is transferred to the melter/gasifier by
means of a screw conveyer. Final reduction of DRI and conversion
of solid feed to hot metal takes place in the melter/gasifier. Hot metal
tapping and slag are removed via separate tapping launders
(procedure similar to that for a blast furnace).

Direct Smelting
Technologies for fines ore
Fastmelt
Hismelt

Fastmelt Technology

Fastmelt Bricket &Hot DRI

Fastmelt Hirohata&Kakogawa

Fastmelt Route

Fastmelt Rotary Burner

Hismelt Technology

Hismelt Route

Hismelt SRV

Hismelt Kninawa Australia