Mata Kuliah

Pirometallurgy - 2018

Kuliah 8
Application of Pirometallurgy:
Ironmaking-Steelmaking
 Hydrometallurgy vs. Pyrometallurgy
Hydrometalurgy Pyrometallurgy
Treat high grade Less economic More economic
ore?
Treat low grade ore? Possible with Unsuitable
selective leaching
Treat sulphide ore No SO2; otherwise SO2 generated (can
So or SO42- are be converted to
generated H2SO4)
Separate similar Possible with certain Not possible
metal, such as Ni method
and Co
Pollutant Waste water, Gases and dust
solid/slurry residues
Reaction rates Slower Rapid
 Hydrometallurgy vs. Pyrometallurgy
Hydrometalurgy Pyrometallurgy
Scale of operation? Possibly economic to Unconomic at smale
be done at small scale operation
scale operation and
expansion is easier
Capital cost Generally lower than Higher
pyrometallurgy
Energy cost Lower Higher
Materials Handling Slurry Easy to be Handle Molten
Pumped and Metal, Slag,
Transported Matte
Residues Residues – Fine Slags – Coarse
and Less Stable and Stable
 Indonesia mineral deposit

Mineral Ore Metal %ore

Gold 2,807,151,814 2,575 0.00.= 9.2 ppm
Bauksit 585,721,415 239,598,060 40.91
Nickel 1,155,234,951 21,378,312 1.85
Copper 1,719,650,376 25,603,197 1.49
Iron 65,579,511 39,825,354 60.73
Mangan 4,429,029 2,834,916 64.01
Zinc 19,864,090 2,274,982 11.45
 Step on Pyrometallurgy Process

Pyrometallurgy: using high temperatures to obtain the

free metal.

Several steps are employed:

Calcination is heating of ore to cause decomposition

and elimination of a volatile product (CO2 or H2O):

PbCO3(s)  PbO(s) + CO2(g)

 Step on Pyrometallurgy Process
Roasting is heating which causes chemical reactions
between the ore and the furnace atmosphere:

2ZnS(s) + 3O2(g)  2ZnO(s) + 2SO2(g)

2MoS2(s) + 7O2(g)  2MoO3(s) + 4SO2(g)
 Step on Pyrometallurgy Process

Smelting is a melting process that causes materials to

separate into two or more layers.

Slag consists mostly of molten silicates in addition to

aluminates, phosphates, fluorides, and other inorganic
materials.

Refining is the process during which a crude, impure

metal is converted into a pure metal.
 8

World steel society

 Steel consumption is one of indicator of cultural and life level.

[1] World Steel Association, 2011. Steel statistical yearbook 2011.; [2] The Japan Iron and Steel federation. ; [3] http://1ms.net/chevrolet-camaro-indianapolis-500-pace-car-221845.html; [4]
http://atlazcrew-world.blogspot.jp/2012/04/my-dream-jalur-lintas-nusantara.html
 9
World steel society
20
Crude steel production
[102 million ton]

15

10

World crude steel production

5
2002 2004 2006 2008 2010 2012
Year [-]

 The steel demand would increase significantly to fulfill to world economic

growth, especially in developing country.
[1] World Steel Association, 2011. Steel statistical yearbook 2011.; [2] The Japan Iron and Steel federation. ; [3] http://1ms.net/chevrolet-camaro-indianapolis-500-pace-car-221845.html; [4]
http://atlazcrew-world.blogspot.jp/2012/04/my-dream-jalur-lintas-nusantara.html
Steel production compared to other material
Steel Recycle
Overview process and products
 Ironmaking industry 13

World energy consumption

 World economic growth required highly steel based material

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

[5] International Energy Agency, 2008. Worldwide trends in energy use and efficiency; [2] The Japan Iron and Steel federation. ;
[6] http://www.syntropolis.net/knowledgehub/wiki/energy-efficiency-in-industry/
 Ironmaking industry 14

Typical energy source in Ironmaking

industry Japan CO2 emission (industrial sector)

 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.
Steel production route (overall)

 Blast Furnace (BF) – Basic Oxygen Furnace (BOF)

 Direct Reduction (DR) – Electric Arc Furnace (EAF)
Steel production route 1 : BF-BOF
Steel production route 2 : DR-EAF
Steel production route at PT. Krakatau Steel (KS)
 Ironmaking industry 19

Iron and steel production

Finishing process

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

[8] http://www.profisol.gr/en/production/steelmaking.aspx .; [2] The Japan Iron and Steel federation.

Ironmaking industry 20

Blast Furnace operation

BF gas
Solid
flowing Reactions:
Iron ore 200oC 3Fe2 O 3  CO  2Fe3O 4  CO2 ;
Fe3O 4  CO  3FeO  CO2
Coke (C) 500oC 2CO  C  CO2
FeO  CO  Fe  CO 2
900oC
FeO  CO  Fe  CO2
1200oC FeO  C  Fe  CO
C  CO2  2CO

C  CO2  2CO
1700oC
C  O 2  CO2
Gas
flowing

 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
Raw Material: Iron Ore
 Raw Material: Iron Ore
Magnetite
 Raw Material: Iron Ore
Hematite
 Raw Material: Iron Ore
Hydrous Oxide / Geothite
 Raw Material: Iron Ore
Ilmenite
Indonesia Iron Ore Deposit
Indonesia Iron Ore Deposit
 Assignment 1
Steel production route (overall)

 Blast Furnace (BF) – Basic Oxygen Furnace (BOF)

 Direct Reduction (DR) – Electric Arc Furnace (EAF)

Make a paper review related to one of the detail process:

No absen Ganjil : BF-BOF
No absen genap : DR-EAF
TERIMA KASIH

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