Colloquium tekMIRA 2015

Clean Technology for Mineral and Coal Processing

as An Effort to Increase Added Value

Proposed
Technology
Indonesian Iron Sand

to

Tomi Purwono
Bandung, 3 4 November 2015

Process

Agenda

Overview PT Jogja Magasa Iron

Characteristic of iron sand
Beneficiation process of iron sand
Reduction process of iron sand
Smelting process of iron sand
Conclusion

Overview PT Jogja Magasa Iron

PT Jogja Magasa Iron established in 2008 which is joint

venture company between Indomines Ltd (70%) and PT
Jogja Magasa Mining.
PT Jogja Magasa Iron was entered into the Contract of Work
(CoW) in November 2008 that located along the coast
between the Progo and Serang river.
PT Jogja Magasa Iron are focusing in the mining and
processing of iron sand to produce pig iron with the
capacity 340,000 350,000 tpa of pig iron.

Characteristic of iron sand

Make sure for raw material characteristic before process

design is decided.
Raw material characteristic can be obtained from :
1. Mineralogical analysis
2. Chemical analysis
3. Physical analysis

Mineralogical Analysis of Iron Sand

XRD Analysis

Optical Mineralogical Analysis

Mineral

%-wt

Amorphous

23

Plagioclase
Feldspar

44

Magnetite

Pyroxenes

19

Amphibole

Talc

Total

100

Chemical and Physical Analysis Iron Sand

Head Assay
Assay (%)
Fe Tot

Al2O3

SiO2

CaO

MgO

TiO2

V2O5

P2O5

SO3

13.51

10.94

40.43

11.13

7.36

1.93

0.10

0.36

0.03

Physical Analysis
Visual Identification

Course, overall light colored, discrete mineral species, low

fines

Bulk density

1.9 t/m3

Beneficiation Process of Iron Sand

How to decide process design for concentrator plant?

1. We have a raw material characteristic
2. We have a target requirement related quality and
quantity of product for next process
3. We have to conduct the test work

1. Iron sand shall be processed by magnetic separation,

grinding, and classifying.
2. Requirement of iron sand concentrate for reduction process
are 58% Fe and capacity 645.000 tpa.
3. JMI has conducted the test work with the following test flow :
Flow Process of the Test
Work
Iron
Sand
LIMS @2000G
Grind @p100 =
63m
LIMS @1000G
LIMS @800G
LIMS @600G
LIMS @300G
Concentrate
8

What is the result of the test work?

The final result generated are Fe 58.4% and p80 = 42
micron.
12.1% of yield material and 52.3% of Fe recovery.
Consider to plant working hours is 6624 hours per year
so the total of raw material are needed is 5,375,000 tpa
to produce 645,000 tpa of concentrate.
Process flow diagram
Final Process Flow Diagram of Concentrator
Plant

1.
2.
3.
4.
5.
6.

Iron sand
LIMS
Ball mill
Hydro cyclone/
screening
LIMS
Vertical Mill

Hydro cyclone/
screening
8.
LIMS
9.
LIMS
10. LIMS
11. LIMS
12. Concentrate

1
0

1
1

7.

1
2

Reduction Process of Iron Sand

New Zealand Steel as reference for iron sand processing
New Zealand Steel (NZS), located near Glenbrook, 60 km
south of Auckland, is an integrated producer of 550,000
tones of flat and coated product per annum. Alternative
iron making at NZS comprises direct reduction in four
Multi Heart Furnaces and Rotary Kiln followed by melting
in two Electric Melters utilizing locally available
titaniferous iron sand and high volatiles sub bituminous
B coal(1).

(1) Christopher R, NZS, Presented at the 2000 ISS Electric Furnace

Conference

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Comparison of raw material

Iron Sand Concentrate
Assay
(%)

NZS

Fe Tot

Coal

JMI

Analysis (%)

NZS

JMI

53.4
54.7

46.2

58.4

Fixed
Carbon

58 59.5

Al2O3

3.8 4.8

3.72

Volatiles

50.8

SiO2

2.0 3.0

2.19

45.3
46.6

CaO

0.4 1.3

0.71

5.2 6.0

MgO

2.8 3.2

2.54

Sulphur

0.25
0.31

0.18

TiO2

7.7 8.1

8.58

Moisture

19 23

40.5

V2O3

0.42
0.48

2.88
10.21

19.8

V2O5
P
Size
(p80)

Ash

Reactivity
(h-1)
0.48

0.05
0.07

0.09

149 m

42 m

11

NZS Reduction
Process

DRI to
Smelter

Iron sand
concentrate
Coal

Multi Hearth
Furnace

Rotary Kiln

JMI Reduction Process

Coal
Multi Hearth
Furnace

Off gas

Iron sand
concentrate
Bentonit
e

Pelletizer

Pre hardening
grate

Rotary Kiln

DRI to
Smelter
12

Coal Analysis (HRL Laboratory Australia)

Dry and de volatilize of coal (char)
Provide a consistent composition of char for reduction
process
Pelletizing test work (tekMIRA Laboratory Indonesia)
Provide pellet with a proper metallurgical properties
Coal pyrolysis behaviour
Pellet properties
Analysis

Coal

Char
Pyrolysis

Analysis

Proximate

Size (mm)

9 -16
252

Moisture (%)

Compression
strength (kg)

40.5

Ash (yield
815o C)

3.0

5.5

Volatile
matter (%)

50.8

n/a

Fixed carbon
(%)

46.2

n/a

69.1

89.6

5.0

0.6

0.97

1.30

0.18

0.20

Ultimate

n/a : not analyzed

13

Smelting Process of Iron Sand

DRI from
reduction

Dolomite
Limestone

O2
Sub merged Arc
Furnace
Sla
g

Titanium rich slag

Hot metal

VR
U

Pig caster

Pig iron

Vanadium slag

14

Material description and utility consumptions

Material

Utility
Annual
Throughput

Utility

Total

Power

80 MW

Mined iron sand

5,375,000

Fuel

27 GJ/h

Iron sand
concentrate

645,000

Nitrogen

2 Nm3/h

Coal (for reduction)

442,000

Oxygen

301 Nm3/h

Coal (for power)

220,000

Compressed
air

1869 Nm3/h

Limestone (for
smelting)

15,000

Industrial
water

665 kl/h

Limestone (for coal

boiler)

3,400

Demine water

20 kl/h

Dolomite (for
smelting)

12,000

Domestic
water

3 kl/h

Bentonite binder

6,000

Inputs

15

Conclusion
1. Characteristic of raw material is very important before the
process design is decided.
2. New Zealand Steel as reference for iron sand processing,
technology process from upstream to downstream has proven
for iron sand.
3. Iron sand concentrate of JMI is finer than NZS, agglomeration
process is needed to produce pellet before reduction process.
4. JMI coal is high reactivity, high volatile matter, high moisture
content and low ash, charring is needed to produce char as
material for reduction process.
5. JMI will recover vanadium on smelting process as by product
with high value added.

16

Thank You

17