Proses Pengolahan Ferronickel

Feni Plant UBPN Pomalaa

Oleh
Ulil Amri Nizhamul

Kuliah USN Kelas Antam

Pomalaa, 19 Januari 2019
What is FERRONICKEL used for ?

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What is FERRONICKEL used for ?

Ferronickel Stainless Steel

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Ferronickel Processing
on Pomalaa Feni Plant
Nickel Ore Spesification

• Saprolite Ore
• High Grade Saprolite Ore (HG)
• Ni > 2,0% ; Fe < 25%
• Low Grade Saprolite Ore (LGSO)
• Ni: 1,8% - 2,0% ; Fe < 25%

 Limonite Ore
• Low Grade (LG)
• Ni : 1,2% - 1,8% ; Fe ≥ 25%
FeNi Flow Process
STOCK PILE
Raw Material Preparation
ANTHRASIT
SOM
COAL
STACK RD COAL
COAL LIMESTONE ORE MIXING AIR
AIR STACK RK CYCLONE

E/P ROTARY KILN

RFS & IB

ROTARY DRYER WEIGHING SCALE

HAG SURGE
HOPPER ID FAN
HOPPER

PELETIZER

CRANE Smelting Refining Casting Feni Product

C O N T A I N E R SH A F T

CALCINE BIN STACK EF

GAS KE RD O2
FLUX STACK REFINING INGOT

DCS
De-S FENI PRODUCT
CASTING MACHINE
SLAG CRUDE
TROMMOL SCREEN
CONTAINER CAR

ELECTRIC FURNACE SHOT

SHAKING CONVERTER
Pre – Reduction
STOCK PILE
Raw Material Preparation
ANTHRASIT
SOM
COAL
STACK RD COAL
COAL LIMESTONE ORE MIXING AIR
AIR STACK RK CYCLONE

E/P ROTARY KILN

RFS & IB

ROTARY DRYER WEIGHING SCALE

HAG SURGE
HOPPER ID FAN
HOPPER

PELETIZER

CRANE Smelting Refining Casting Feni

Product
C O N T A I N E R SH A F T

CALCINE BIN STACK EF

GAS KE RD O2
FLUX STACK REFINING INGOT

DCS
De-S FENI PRODUCT
CASTING MACHINE
SLAG CRUDE
TROMMOL SCREEN
CONTAINER CAR

ELECTRIC FURNACE SHOT

SHAKING CONVERTER
Pre Reduction

- Blending Spesification :
SiO2/Mg
Ni Fe Fe/Ni SiO2 BC MC
Analisa O
Unsur
>1.8 <16 ≤ 7.5 >38 <2.2 >0.48 31 - 34
- Sizing

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If, High Iron Content (Fe> 16%)

Fe Ore > 16 %

Klinker Stop Production Production

ROTARY Power Consumption 

Low Temp Calcine Cost
KILN

LOI > 1 Safety

ELECTRIC
Slag Handling Lowering Furnace Power Production
FURNACE

Difficult to tapp Safety

If, Low Silica Content (SiO2< 38%)

Fe Ore > 16 %

ROTARY
High Reductor High Reductor (Coal/Ant) Cost
KILN

ELECTRIC High Reductor /

Equipment Damage Cost
FURNACE High Combusition

Low Si metal Silica Reversion Production

Safety

Difficult to tapp Safety

Energy Distribution of Stainless Steel Making

T.E. Norgate, S. Jahanshahi and W.J. Rankin . ALTERNATIVE ROUTES TO STAINLESS STEEL – A LIFE
CYCLE APPROACH
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Uses of Nickel

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Pre Reduction

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Pre Reduction

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Pre Reduction

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Pre Reduction

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Pre Reduction
Kiln Temperature Profile

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Pre Reduction

Pelletizing

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Pre Reduction
Pelletizing

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Smelting
STOCK PILE
Raw Material Preparation
ANTHRASIT
SOM
COAL
STACK RD COAL
COAL LIMESTONE ORE MIXING AIR
AIR STACK RK CYCLONE

E/P ROTARY KILN

RFS & IB

ROTARY DRYER WEIGHING SCALE

HAG SURGE
HOPPER ID FAN
HOPPER

PELETIZER

CRANE Smelting Refining Casting Feni

Product
C O N T A I N E R SH A F T

CALCINE BIN STACK EF

GAS KE RD O2
FLUX STACK REFINING INGOT

DCS
De-S FENI PRODUCT
CASTING MACHINE
SLAG CRUDE
TROMMOL SCREEN
CONTAINER CAR

ELECTRIC FURNACE SHOT

SHAKING CONVERTER
Smelting

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Smelting

Slag
Metal

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Smelting
Crude Fe-Ni Composition

Slag Composition

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Smelting
Electric Furnace Operation Mode

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Refining
STOCK PILE
Raw Material Preparation
ANTHRASIT
SOM
COAL
STACK RD COAL
COAL LIMESTONE ORE MIXING AIR
AIR STACK RK CYCLONE

E/P ROTARY KILN

RFS & IB

ROTARY DRYER WEIGHING SCALE

HAG SURGE
HOPPER ID FAN
HOPPER

PELETIZER

CRANE Smelting Refining Casting Feni

Product
C O N T A I N E R SH A F T

CALCINE BIN STACK EF

GAS KE RD O2
FLUX STACK REFINING INGOT

DCS
De-S FENI PRODUCT
CASTING MACHINE
SLAG CRUDE
TROMMOL SCREEN
CONTAINER CAR

ELECTRIC FURNACE SHOT

SHAKING CONVERTER
Refining

Shot De-S LD
LC
Metal Tapp Oxygen De-S Blow O2
Lancing Casting
LD
Converter

Shot
De-S
HC
Metal Tapp Oxygen De-S Oxygen
Casting
Lancing Lancing

KOMPOSISI KIMIA (%)

JENIS
No
PRODUK Ni Co C Si P S Cr Mn Cu MC

LOW CARBON
1 18 – 25 Max 1/30 Ni Max 0,03 Max 0,03 Max 0,03 Max 0,03 Max 0,2 Max 0,1 Max 0,08 Max 0,03
SHOT

HIGH CARBON
2 18 – 25 Max 1/30 Ni Max 2,5 Max 2,5 Max 0,03 Max 0,03 Max 2,5 Max 0,20 Max 0,10 Max 0,03
SHOT
Refining

Desulfurization

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Refining
Decarburization & Desilliconization

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Refining

Shot De-S LD
LC
Metal Tapp Oxygen De-S Blow O2
Lancing Casting
LD
Converter

Shot
De-S
HC
Metal Tapp Oxygen De-S Oxygen
Casting
Lancing Lancing

KOMPOSISI KIMIA (%)

JENIS
No
PRODUK Ni Co C Si P S Cr Mn Cu MC

LOW CARBON
1 18 – 25 Max 1/30 Ni Max 0,03 Max 0,03 Max 0,03 Max 0,03 Max 0,2 Max 0,1 Max 0,08 Max 0,03
SHOT

HIGH CARBON
2 18 – 25 Max 1/30 Ni Max 2,5 Max 2,5 Max 0,03 Max 0,03 Max 2,5 Max 0,20 Max 0,10 Max 0,03
SHOT
Casting
STOCK PILE
Raw Material Preparation
ANTHRASIT
SOM
COAL
STACK RD COAL
COAL LIMESTONE ORE MIXING AIR
AIR STACK RK CYCLONE

E/P ROTARY KILN

RFS & IB

ROTARY DRYER WEIGHING SCALE

HAG SURGE
HOPPER ID FAN
HOPPER

PELETIZER

CRANE Smelting Refining Casting Feni

Product
C O N T A I N E R SH A F T

CALCINE BIN STACK EF

GAS KE RD O2
FLUX STACK REFINING INGOT

DCS
De-S FENI PRODUCT
CASTING MACHINE
SLAG CRUDE
TROMMOL SCREEN
CONTAINER CAR

ELECTRIC FURNACE SHOT

SHAKING CONVERTER
Casting

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Casting

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Terima Kasih….
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