BIJIH BESI & AGLOMERISASI

Prof. Dr.-Ing. Bambang Suharno

Kuliah 2 Pembuatan Besi Baja

Metallurgy and Materials Engineering Department

University of Indonesia
Semester Genap 2020-2021
University of
Materi Kuliah
Indonesia

 Bahan Baku Pembuatan Baja

 Bijih Besi (Iron Ore)
 Benefiasiasi Bijih Besi
 Proses Pelletasi
 Proses Sinter
 Pengolahan Bijih Besi Skala UKM

Metallurgy and Materials Engineering Department UI

University of
Indonesia

Metallurgy and Materials Engineering Department UI

 Bahan Baku Proses Pembuatan Besi
University of
Indonesia
Baja
 Iron Ore (Bijih Besi)
 Reduktor
 Coke (Blast Furnace)
 Coal (Reduksi Langsung dan Smelting
Reduction)
 Natural Gas (CH4) (Reduksi Langsung)
 Scrap (Baja Bekas)
 Additive (Flux): CaO (Batu Kapur)

Metallurgy and Materials Engineering Department UI

University of
Jenis Bijih Besi (Iron Ore)
Indonesia

 Jenis oksida (terbanyak)

(Fe3O4 = Magnetit  Fe ≈ 72,4 %
Fe2O3 = Hematit Fe ≈ 70 %
 Jenis Hidroksida  Fe ≈ 50 % - 55 %
Fe2O3.nH2O = Hydrohematite/Laterit
Fe2O3*H2O = Goethit
Fe2O3*3 H2O = Limonit
 Jenis karbonat
FeCO3 = Siderit  Fe ≈ 48,2 %
 Jenis Titanious Ferrous
FeO.TiO2 = Pasir Besi/Ilmenit  Fe ≈ 36,8 %, Ti ≈ 5-13 %
 Jenis Sulfit
(FeS2 = Sulfit  Fe ≈ 46,7 %

Metallurgy and Materials Engineering Department UI

 Chemicals composition of iron ores
University of
Indonesia
from various countries (wt %)

Metallurgy and Materials Engineering Department UI

University of
Iron Ore Mining (Brazil) High Grade
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Lateritic Iron Ore (Indonesia)
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Iron Sand (Pasir Besi) Indonesia
Indonesia

Konsentrat

Dialam

Metallurgy and Materials Engineering Department UI

University of
Persyaratan Bijih Besi
Indonesia

 High Iron content

 Minimum impurities (S, P, As, Zn, Pb, Na, K,)
 High content of basic oxides in gangue (self fluxing
ore), CaO, MgO
 Minimum derivation in chemicals composition
 High reduceability
 High strength
 Minimum of fines and narrow size distribution (for a
uniform gas flow)

Metallurgy and Materials Engineering Department UI

 Sebaran Bijih Besi Lokal
University of
Indonesia

Metallurgy and Materials Engineering Department UI

 14

University of
Deposit Bijih Besi Indonesia
Indonesia

Sumber Daya Terukur

Jenis Deposit Bijih
Besi
Ton Lokasi

Methasomatic Ore Lampung, West of Sumatera,

320.462.611 Belitung, west of Kalimantan,
(Besi Primer) Tanalang, Plaihari, dll.

South of Kalimantan, Pomalaa,

Lateritic 1.391.246.630
Halmahera, dll.

South of Java Island Coast,

Iron Sand 382.000.000 Sumbar, Bengkulu, NTB, Sulsel
dll.
Sumber : Direktorat Mineral Batubara ESDM

Metallurgy and Materials Engineering Department UI

 POTENSI BIJIH DI INDONESIA DAN
TEKNOLOGI PROSES
University of
Indonesia

Cadangan bijih besi di Indonesia

(Indonesian Mining Journal, No
11, Vol.11, June 2008)

Bijih besi Teknologi

Bijih besi primer (hematit, Blast furnace, Direct reduction (rotary
magnetit) kiln)
Bijih besi laterit Direct reduction (rotary kiln)
Pasir besi Direct reduction (rotary kiln / fluidized
Metallurgy and Materials Engineering Department UI
bed)
 PENINGKATAN NILAI JUAL MULAI BAHAN BAKU SAMPAI PRODUK JADI PADA
INDUSTRI BESI BAJA
University of
Indonesia

800
700
HRC
600
SLAB
500
$ / TON

400 PIG IRON

300
200 PELET
KONS
100
ORE
0
1 2 3 4 5 6

Metallurgy and Materials Engineering Department UI PT KRAKATAU STEEL

 Bijih besi

University of
Indonesia Fe tinggi Fe rendah

Pemurnian
> 6 mm < 6 mm
konsentrat ( Fe tinggi )
ukuran rendah

Aglomerisasi (Pellet , Sinter)

> 6 mm
Lump ore
Pellet
Export
Blast Furnace = Pig Iron (Hot Metal)
Reduksi Langsung = Sponge Iron

Ukuran 6 mm  batas undersize yang masih dapat diolah Sinter

Umumnya berukuran 12 – 30 mm
Metallurgy and Materials Engineering Department UI
University of
Proses pemurnian Bijih Besi
Indonesia

 Meningkatkan kandungan Fe pada ‘low grade raw ore”

 Memisahkan senyawa yang tidak diinginkan
 Penghalusan ukuran bijih besi (< 2 mm) untuk dapat
dibuat pellet
 Proses yang dilakukan antara lain:
 Washing of ore
 Crushing/ grinding
 Gravimetry (Classifier)
 Magnetic separator
 Flotation
 Iron ore yang sudah dimurnikan disebut
“KONSENTRAT”

Metallurgy and Materials Engineering Department UI

 Crushing dan Screening
University of
Indonesia

Metallurgy and Materials Engineering Department UI

 Milling dan Spiral Classifier
University of
Indonesia

Metallurgy and Materials Engineering Department UI

 Magnetic Separator Process
University of
Indonesia

Metallurgy and Materials Engineering Department UI

 Bahan Baku Pasir Besi (Raw
University of
Indonesia
Material)
• Sumber bahan baku Cipatujah, Tasikmalaya berada di
lokasi: Cidadap, Ciheras, Cimanuk, Cikaung Gading.

• Kandungan
• Fe = 35-40%
• TiO2 = 5 – 15%
Cidadap Ciheras

Cimanuk Cikaung Gading

Metallurgy and Materials Engineering Department UI
 Konsentrat Pasir Besi (Ore
University of
Indonesia
Treatment)
Pasir Besi

Magnetic Separator

Konsentrat

CMPFA Metalurgi UI

Metallurgy and Materials Engineering Department UI

 Spiral
Classifier
University of
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Indonesia

LATERITE IRON ORE

Metallurgy and Materials Engineering Department UI
University of
Indonesia

IRON ROCK
Metallurgy and Materials Engineering Department UI
 V. LAMPIRAN PERMEN ESDM NO. 1 TAHUN 2014
Pengolahan
Komoditas
No. dan/atau Produk Batasan Minimum Kegunaan Gambar
University of Bijih/ore
Pemurnian
Indonesia
4. Bijih besi Pengolahan Konsentrat ≥ 62% Fe Bahan pembuatan
besi sponge iron dan pig
iron

Pengolahan Konsentrat ≥ 51% Fe Bahan pembuatan

besi laterit Kadar (Al2O3 + SiO2) > 10% sponge iron dan pig
iron

Pemurnian Spon, logam Besi spon (sponge iron) ≥ Bahan pembuatan pig
dan logam 75% Fe; iron
paduan

Besi wantah (pig iron) ≥

90% Fe; dan/atau
Bahan pembuatan besi
dan baja

Logam paduan (alloy) ≥ Bahan pembuatan

88% Fe. bantalan rel kereta api,
peralatan industri
pertambangan,
otomotif, konstruksi, dll
Metallurgy and Materials Engineering Department UI
 V. LAMPIRAN PERMEN ESDM NO. 1 TAHUN 2014
Pengolahan
Komoditas Batasan
No. dan/atau Produk Kegunaan Gambar
University of Bijih/ore Minimum
Pemurnian
Indonesia
5. Pasir besi Pengolahan Konsentr ≥ 58% Fe; Bahan pembuatan
at pasir dan/atau sponge iron dan pig
besi iron

Konsentrat Pasir Besi

Pelet > 56% Fe. Bahan pembuatan
sponge iron dan pig
iron

Pelet
Pemurnian Logam a. Besi spon Bahan pembuatan
(sponge pig iron
iron) ≥ 75%
Fe;
dan/atau

b. Besi
wantah (pig Bahan pembuatan
iron) ≥ 90% besi dan baja
Fe.

Metallurgy and Materials Engineering Department UI

University of
Alasan Aglomerisasi
Indonesia

 Tidak semua bijih besi memiliki kadar Fe

tinggi untuk diolah di tanur tinggi atau tanur
lainnya
 Ukuran yang seragam diperlukan agar :
 optimum rate of gas flow
 uniform gas flow , with a minimum of
channeling
 Ukuran partikel kecil , menyebabkan adanya
sejumlah fine material yang keluar tanur dan
masuk ke ‘gas recovery’ system

Metallurgy and Materials Engineering Department UI

University of
Proses Aglomerisasi
Indonesia

 Kriteria pemilihan
 ukuran partikel > 2 mm 
sinter
 ukuran partikel < 0,2 mm 
pellet
 Lokasi Pembuatan
 Sinter  biasanya dekat TT
 Pellet  biasanya dekat
penambangan

Metallurgy and Materials Engineering Department UI

University of
Penggunaan Pellet dan Sinter
Indonesia

 Europa Union : 65% sinter, 24% pellet, 13% lump ore

 Brazil, Japan, Korea Selatan: > 70% sinter
 Canada, USA: 91 dan 81% pellets
 Penggunaan Lump ore pada blast furnace dibatasi
tak lebih dari 10 – 15%
 Pada blast furnace sebetulnya memungkinkan untuk
mengolah bijih besi dengan berbagai kadar Fe.
Namun semakin tinggi kadar Fe akan semakin
ekonomis

Metallurgy and Materials Engineering Department UI

University of
Proses Pembuatan Pellet
Indonesia

 Dikembangkan dalam rangka pemanfaatan bijih besi

yang halus
 Green pellet (pellet mentah)
 Partikel bijih besi halus yang dicampur oleh air dan
bentonit, digumpalkan melalui proses rotasi sehingga
terjadi bola-bola aglomerat (kekuatan 20 – 50 N/ pellet)
 Burn pellet (pellet bakar)
 bola-bola aglomerat dikeraskan dengan cara dibakar
pada: conveyor belt, grate kiln atau shaft furnace
 (kekuatan hingga 2500 N/ pellet)

Metallurgy and Materials Engineering Department UI

University of
Pellet Mentah (Green Pellet)
Indonesia

Bijih besi halus dengan campuran

Bentonit : 8,3 - 10 kg/ ton of feed
% air : (4-7%)

ukuran pellet : ± 8 – 30 mm
β  biasanya 10 – 15 mm

Kekuatan Green pellet :

20 – 50 N / pellet

Metallurgy and Materials Engineering Department UI

University of
Pelletasi
Indonesia

Faktor penentu
 kadar air harus optimal
 kehalusan partikel
 penambahan bentonit
 kadar bahan sampingan
 diameter , kecepatan piringan

 jika kekuatan green pellet rendah  dibakar (T = 1000 oC)

 agar kekuatan : 2500 N/pellet
 Alat : Shaft furnace
Grate kiln
Traveling gate / conveyor belt
Metallurgy and Materials Engineering Department UI
University of
Proses Pelletasi
Indonesia

Metallurgy and Materials Engineering Department UI

 Parameters of the discs for
University of
Indonesia
production of green pellet

Metallurgy and Materials Engineering Department UI

University of
Pellet Bakar (Burn Pellet)
Indonesia

 Dibakar 1000 OC, kekuatan : 2500 N/pellet

Grate Kiln

Traveling gate / conveyor belt

Shaft Furnace

Metallurgy and Materials Engineering Department UI

University of
Pembakaran Pellet
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Properties of Iron Ore Pellets
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Campuran Sinter
Indonesia

 Iron bearing fines ( 50-60% of raw mix, grain sixe 0-

10 mm, incl. 70%> 0,2mm)
 Solid fuel (3-4% coke breeze 0-3mm)
 Flux (10-15%, grain size <3mm, limestone, lime,
dolomite)
 Circulating materials (4.5 – 5%, mill scale, BF and
BOF dusts)
 Return sinter fines (25-35%, grain size < 6.3 mm)
 Moisture (water 5-9%)

Metallurgy and Materials Engineering Department UI

University of
Proses Sinter
Indonesia

Dalam proses ini bijih besi < 5 mm dicampur dengan

cokes breeze :8% (bahan bakar)
air : 5-9 % (kemampuan ikat Fe tinggi)
Bahan sirkulasi : 25 – 35 %
Additiv : 10-15 % (CaO , Dolomit)

Dicampur (mixing drum)

Sinter machine
( lebar : ± 4 m ) kecepatan : 5 – 9 m/menit
(panjang : ± 100 m)

Metallurgy and Materials Engineering Department UI

University of
Sinter Machine
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Proses Sinter
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Mesin Sinter
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Produk Sinter
Indonesia

Metallurgy and Materials Engineering Department UI

 Requirements on physical and
University of
Indonesia
metallurgical properties of sinter

Metallurgy and Materials Engineering Department UI

 Operation Data of Sinter Plant in
University of
Indonesia
Germany

Metallurgy and Materials Engineering Department UI

 European
University of sinter plants
Indonesia

Metallurgy and Materials Engineering Department UI

University of
Proses Sinter
Indonesia

Umpan sinter diletakkan dalam alat panggang & dibakar

permukaannya (1300 – 1480 oC)
Setelah terbakar  udara panas dihisap dari atas ke bawah
zona pembakaran bergerak dari atas ke bawah

h = 40-45 cm

dihisap Terbentuk sinter  pemecah  ukuran 6 – 25 mm (didinginkan)

< 6 mm  disirkulasikan

Metallurgy and Materials Engineering Department UI

University of
Proses Sinter
Indonesia

Metallurgy and Materials Engineering Department UI

 Material Batu Besi daerah Garut
University of
Indonesia

Metallurgy and Materials Engineering Department UI

 Mesin Crushing/ Ball Mill
University of
Indonesia

Metallurgy and Materials Engineering Department UI

 Mesin Pencampur
University of
Indonesia

Metallurgy and Materials Engineering Department UI

 Mesin Pelletasi
University of
Indonesia

Metallurgy and Materials Engineering Department UI

 Dapur pembakaran pellet mentah
University of
Indonesia

Metallurgy and Materials Engineering Department UI

 Generator Listrik
University of
Indonesia

Metallurgy and Materials Engineering Department UI