Pengolahan Mineral

Kuliah 1 dan 2
Pendahuluan

Prof. Dr. Ir. Johny Wahyuadi Soedarsono, DEA

Departemen Metalurgi dan Material
Fakultas Teknik Universtas Indonesia
Pebruari 2024
 Metallurgy
The science and technology to
extract the desired metal from its
naturally occurring ore through
physical and chemical processes.
 Metallurgy
Metallurgy is the science and
technology of metal. It is the oldest
of the sciences devoted to the study
of engineering materials.
Metallurgy has evolved into three
separate groups: extractive,
mechanical, and physical.
 Extractive Metallurgy

Benefication, mineral dressing,

pyrometallurgy,
hydrometallurgy, and
electrometallurgy.
 Mineral Processing Methods =
beneficiation + extractive metallurgy
Cycle of Materials
 Life Cycle of a Metal Resource

Surface Metal ore Separation Smelting Melting Conversion Discarding

mining of ore from metal to product of product
gangue
Recycling

Smelting – heating to release metals but creating air polluting by-products

Chemical removal processes such as using cyanide to remove gold can create
Toxic holding ponds
 Minerals

How Minerals Form

1. Crystallization from magma
2. Precipitation
3. Pressure and temperature
4. Hydrothermal solutions
Minerals Formed as a Result of Crystallization
of Magma
 Minerals

Mineral Groups
 Can be classified based on their
composition
1. Silicates
• Silicon and oxygen combine to form a structure
called the silicon-oxygen tetrahedron. This
silicon-oxygen tetrahedron provides the
framework of every silicate mineral.
 Minerals

Mineral Groups
2. Carbonates
• Minerals that contain the elements carbon,
oxygen, and one or more other metallic
elements

3. Oxides
• Minerals that contain oxygen and one or more
other elements, which are usually metals
 Minerals

Mineral Groups
4. Sulfates and Sulfides
• Minerals that contain the element sulfur

5. Halides
• Minerals that contain a halogen ion plus one or
more other elements
6. Native elements
• Minerals that exist in relatively pure form
Sulfides
Common non-silicate minerals

Fluorite – used as a toothpaste additive

Calcite -- calcium carbonate -- Limestone is made of
calcite.
Dolomite -- calcium magnesium carbonate
Gypsum -- calcium sulfate
Galena -- lead sulfide
Pyrite -- iron sulfide
Halite -- sodium chloride (table salt)
Mohs Scale of Hardness
 Ore Processing
A wide diversity of physical and chemical
processes are included in this term, which often
is given as mineral dressing, ore dressing, or
beneficiation.

Ore processing covers all the means that

regulate the size of a substance, remove
unwanted constituents, and improve the quality,
purity, or assay grade of a commercial product:
for ores, it also involves concentrating or
otherwise preparing them for smelting, by
drying, flotation, or magnetic separation
The steps of obtaining a pure metal generally
follows the following steps :

1) Mining- removing ore from the ground

2) Milling- removing waste materials
3) Smelting- removing more waste material
4) Refining- purifying to pure metal form

Successful application of each step is required

to produce metal at a profit.
 Importance of Metals

 Metals have played a significant role on the

technology and the quality of life of people
 Early history of human technology is divided
into the
 Stone Age (~2,000,000 y),
 Copper Age-Bronze Age (~2000 y)
 Iron Age (~2000 y)
 Importance of Metals

Seven metals are present in today’s jet

engines.
A modern jet engine consists mostly
of Ti and Ni with decreasing amounts
of Cr, Co, Al, Nb, and Ta.
Fe is not present in a modern jet
engine!!!
 Occurrence and Distribution
of Metals

The solid portion of the Earth is called

the lithosphere.
Concentrated metal deposits are
usually found beneath the Earth’s
surface.
 Occurrence and Distribution
of Metals

The metal of interest usually needs

to be extracted from a large
amount of unwanted material
Metals usually need further
treatment to make them suit our
requirements.
Figure 2: The Feedback Control Cycle of Mineral Supply, Increase of Raw
Material Efficiency, and Sustainable Development, F.-W. Wellmer and C.
 Mineral Processing

• Crushing of ores produces tailings

• Traces of pollutants like mercury, arsenic,
cadmium and uranium may leach out of
tailings and contaminate groundwater and
landfills
• Processing chemicals (e.g., Cyanide) are major
hazards (cyanide spill in Danube)
• Smelting releases toxic elements, SO2 etc and
causes acid rain which can destroy vegetation
 Mineral
Solid inorganic compounds found in
nature in the lithosphere.

Ore
A mineral with a sufficient concentration
for the desired material to be
economically exploitable.
 Important Minerals
Names of minerals are based on the
location of their discovery, the
person who discovered them, its
color or some other characteristic
of the mineral.
The most important sources of
metals are oxides, and also sulfides
and carbonates.
Table 1
 What is mining?
 “A process that begins with the discovery of
mineral deposits and continues through ore
extraction and processing to the closure and
remediation of worked out sites”

Mineral Types

Metals Industrial Minerals Construction Minerals Energy Minerals

Copper Borates Clay Coal

Bauxite Diamonds Gravel / Sand Gas
Gold Salt Stone Oil
Iron Talc etc Uranium
etc Titanium(Rutile& Ilmenite)
etc

SOURCE: UNEP 1997, “Mining - Facts and Figures”, ‘Industry and Environment’, Oct.- Dec.
 What is mining?
Iron ore,
Development: Waste rock Crush / Bulk transport coal, stone
•Planning removal
•Land Clearing and mineral wash mineral Industrial
Mineral
•Construction
extraction processing minerals

Exploration: Smelting and Copper,

•Finding Waste disposal
refining aluminium
•Follow Up
•Proving

Support Activities
•Water Extraction
•Land Rehabilitation and Revegetation
•Power Generation
•Maintenance of Equipment / Infrastructure
What are minerals?
Coal Preparation Flow Sheet
Size-Size Solid-Solid Solid-Liquid
Heavy Media
Dewatering
Coarse Vessel
Screens
Raw
Screens

Basket
Centrifuge
Small

Heavy
Media
Deslime
Cyclone
Screens

Coal Spirals Screen-Bowl

Centrifuges
Fine

Classifying
Cyclones

Disc Filter
Ultrafine

Froth
Flotation
 Mining

Five main types of mining:

 Open cast mining

 Underground mining
 Open pit mining
 Dredging
 Solution mining
Open cast mining
Underground mining
Open pit mining
Dredging
Solution mining
Mineral processing and refining
emissions to air

Gravity Pyrometallurgy
separation (usually smelting
(coal, iron copper)
ore)

Crushed / Magnetic Dewatering

separation Electrometallurgy
washed and
(titanium, (Aluminium, lead)
mineral filtration
tungsten)

Flotation Hydrometallurgy
(copper, (gold, nickel,
nickel gold) uranium, zinc)
reagents reagents
tailings
What kind of impacts can we expect?
 Physical  Socio-economic
 Land  Native Title
 Land use  World view
 Biological diversity  Public health
 Energy  Employment
 Water  Violence / alcoholism
 Water use  Education & training
 Water quality
 Community sustainability
 Global warming
 Acidification
 Resources
 Tembaga (area Grasberg)
Kompas, 12 Maret 2019, Produksi sejak 1990 (harga dalam
US$/ Cu 6.300/ton; Emas 42,86 /gr; Perak 0,53 /gr)

Jumlah (ton) Nilai (US$)

 Tembaga 11,8 juta 74,340 M
 Emas 4.600 197,145 M
 Perak 6.450 3,373 M

1 ton bijih tembaga  9,9 Kg Cu; 1,59 Gr Au; 2,23 Gr Ag

Cadangan 1,8 M ton
 Nikel / Terak
Produksi (ton) Nilai (US$)
Nikel 56 jt 711,2 M
Cobalt 718 21,5 M

Terak 1% 560.000
 Timah
 Mineral utama Cassiterite (SnO2 : 3%)
 Bahan baku timah : primer (SnO2 low grade 0,01 –
3%) & sekunder (recycle terak)

 Cadangan 2,3 juta ton

 Harga Logam timah 21.450 US$/ton

Produksi (ton) Nilai (US$)

75.000 1,61 M
 Mineral Ikutan

 1. Monazite
 2. Ilmenite
 3. Xenotime
 4. Zircon
 Monazite
(Ce, Nd, Pr, La)PO4 + Th3 (PO4) 4
 Cadangan 600.000 ton ore
 Thorium 6,81 % (40.428 ton)
 Rare earth 52 % (313.200 ton)

Ilmenite (FeTiO2)
 Cadangan 2,1 juta ton ore
 Titanium oksida 23,46 % (493.021 ton)
 Xenotime (YPO4)
 Cadangan 104,135 ton ore
 Kandungan Y2O3 28,21% (29.382 ton)

Zircon (ZrSiO4)
 Cadangan 440.000 ton ore
 Kandungan Zr oksida 44,55 % (200.000 ton)
KandunganTerak Timah
Selesai