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- 1. Laterite Nickel Ore Processing and Refining by Pyrometallurgy Zulfiadi Zulhan Department of Metallurgical Engineering Faculty of Mining and Petroleum Engineering Bandung Institute of Technology INDONESIA 13th August 2021 MG-4025 Sustainable Process Metallurgy
- 2. 2 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Please do not upload this material to the internet!!!
- 3. 3 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 1 H Hidrogen 1,00784 3 Li Litium 6,938 4 Be Berilium 9,0121831 21 Sc Scandium 44,955908 5 B Boron 10,808 13 Al Aluminium 26,9815385 9 F Fluor 18,9984032 2 He Helium 4,002602 11 Na Natrium 22,9897693 19 K Kalium 39,0983 37 Rb Rubidium 85,4678 55 Cs Cesium 132,905452 87 Fr Francium 223 10 Ne Neon 20,1797 18 Ar Argon 39,948 36 Kr Kripton 83,798 54 Xe Xenon 131,293 86 Rn Radon 222 118 Uuo Ununoktium 294 17 Cl Klor 35,446 35 Br Brom 79,901 53 I Yodium 126,904472 85 At Astatin 210 117 Uus Ununseptium 294 12 Mg Magnesium 24,304 20 Ca Kalsium 40,078 38 Sr Strontium 87,62 56 Ba Barium 137,327 88 Ra Radium 226 39 Y Yttrium 88,90594 22 Ti Titanium 47,867 40 Zr Zirkon 91,224 72 Hf Hafnium 178,49 23 V Vanadium 50,9415 24 Cr Kromium 51,9961 25 Mn Mangan 54,938044 26 Fe Besi 55,845 41 Nb Niobium 92,90637 42 Mo Molibdenum 95,95 27 Co Kobalt 58,933194 28 Ni Nikel 58,6934 29 Cu Tembaga 63,546 30 Zn Seng 65,38 48 Cd Kadmium 112,414 80 Hg Raksa 200,592 47 Ag Perak 107,8682 111 Rg Roentgenium 281 106 Sg Seaborgium 271 43 Tc Teknetium 97 44 Ru Rutenium 101,07 45 Rh Rodium 102,90550 46 Pd Paladium 106,42 79 Au Emas 196,966569 112 Cn Copernicium 285 78 Pt Platinum 195,084 110 Ds Darmstadtium 281 77 Ir Iridium 192,217 76 Os Osmium 190,23 105 Db Dubnium 268 109 Mt Meitnerium 278 108 Hs Hassium 270 107 Bh Bohrium 270 74 W Wolfram 183,84 73 Ta Tantalum 180,94788 104 Rf Ruterfordium 263 75 Re Rhenium 186,207 57 La Lantanum 138,90547 57-71 89 - 103 89 Ac Aktinium 227 58 Ce Serium 140,116 59 Pr Prometium 145 60 Nd Neodimium 144,242 61 Pm Praseodimium 140,90766 62 Sm Samariu m 150,36 90 Th Torium 232,0377 91 Pa Protaktinium 231,03588 92 U Uranium 238,02891 93 Np Neptunium 237 94 Pu Plutonium 244 95 Am Americium 243 96 Cm Curium 247 97 Bk Berkelium 247 98 Cf Californium 251 99 Es Einsteinium 252 100 Fm Fermium 257 101 Md Mendelevium 258 102 No Nobelium 259 103 Lr Lawrencium 262 63 Eu Europium 151,964 64 Gd Gadolinium 157,25 65 Tb Terbium 158,92535 66 Dy Dysprosium 162,500 67 Ho Holmium 164,93033 68 Er Erbium 167,259 69 Tm Tulium 168,93422 70 Yb Ytterbium 173,045 71 Lu Lutetium 174,9668 6 C Karbon 12,0096 7 N Nitrogen 14,00643 8 O Oksigen 15,99903 15 P Fosfor 30,973762 16 S Belerang 32,059 34 Se Selenium 78,971 14 Si Silikon 28,084 32 Ge Germanium 72,630 33 As Arsen 74,921595 51 Sb Antimon 121,760 52 Te Telurium 127,60 84 Po Polonium 209 31 Ga Galium 69,723 49 In Indium 114,818 50 Sn Timah 118,710 81 Tl Talium 204,382 82 Pb Timbal 207,2 83 Bi Bismut 208,98040 116 Lv Livermorium 293 114 Fl Flerovium 289 115 Uup Ununpentium 289 113 Uut Ununtrium 286 Nonmetal Alkali Metal Alkaline Earth Metal Transition Metal Metal Metalloid Halogen Noble Gas Lanthanide Actinide ~80% metals (shiny elements that conduct heat and electricity well) (95/118) ~15% nonmetals (poor conductors of heat and electricity) (17/118) ~5% metalloids (share properties of both metals and nonmetals) (6/118) 28 Ni Nikel 58,6934
- 4. 4 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 1.2 0.7 1.6 0.3 0.4 0.5 0.7 0.1 0.1 0.1 0.9 0.0 0.5 1.0 1.5 2.0 2.5 Mine Product Uses Nickel (Mio. Ton) Nickel Sulfide Ore Limonite Saprolite Laterite Nickel Ore NPI (2-15% Ni) FeNi (15 - 40% Ni) NiSO4 (22% Ni) Other Ni cathode Ni briquette Other (99.9% Ni) Stainless Steel Class 2 Nickel Class 1 Nickel Nickel alloy, Special steel, plating Battery, Other industry Nickel Production and Uses http://sustainability.sherritt.com Vale, Norilsk 2018: 2.2 mio ton Ni https://steinbuch.files.wordpress.com Stainless Steel 56% Nickel alloy 6% Special steel 2% Plating 3% Foundry 1% Battery 27% Other 5% 2030 4,5 juta ton Ni Stainless Steel 73% Nickel alloy 9% Special steel 3% Plating 5% Foundry 1% Battery 8% Other 1% 2020 2,4 Mio ton Ni 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 Nickel Production (mio. ton) Tahun World Ni production Indonesian Ni mine production Indonesian Ni metal production 0 10000 20000 30000 40000 50000 60000 70000 Nickel price (USD/ton) Nickel price UU No. 4/2009 Year MacQuarie, 2021
- 5. 5 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Nickel: Sulfide versus Laterite www.minerals.net Pyrrhotite [(Ni,Fe)7S8] periodictable.com Pentlandite [(Ni,Fe)9S8] Nikel oxide / laterit Nickel sulfide • 1-3% Ni, (Co, Fe) oxides, LOI ~ 10% • Moisture: 30 – 40% • Difficult to do concentration (upgrading) • 1-2% Ni (Cu-Co-Fe) sulfides. • PGM (Au, Ag, Pt, …), As, Se, Te … • S as fuel in the smelting process • Can be concentrated 6 – 20% Ni
- 6. 6 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Bijih Nikel Nikel Sulfide Laterite Nickel Saprolite: Fe: ~15% Ni: > 1,6% Limonite: Fe: ~35% Ni: < 1,6% ▪ Drying ▪ Calcination ▪ Smelting ▪ Leaching ▪ Refining Ferronickel / NPI / Ni-matte Nickel, Cobalt Pentlandit Ni:~1-2%, Cu, Co, Fe, S, Au, Ag, As, Se, Te ▪ Concentrating ▪ Smelting ▪ Refining Nickel, Copper, PGM Resources: 30% Ni-production: 32% Resources: 70% Ni-production: 68% www.panoramio.com www.minerals.net periodictable.com Nikel oksida 68% Nikel sulfida 32% Laterite and Sulfide Nickel Ore Processing and Refining
- 7. 7 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 https://www.tec-science.com/ www.hongjigroup.com Nickel sulfide: 1.5-3% Ni, 1-2% Cu, 0.05-0.1% Co Tailing Ni<0.3% Cu-concentrate Cu-smelting Ni concentrate: 15% Ni, 0.5% Co, Fe, Cu, S www.outotec.com www.911metallurgist.com www.outotec.com 40%Ni, 0.5%Co 0.25% Fe, Cu, S www.alamy.com 50-60% Ni, 1%Co, 1% Fe, Cu, S Cu-Ni-S matte Hydrometallurgy Phase separation Cu-rich fraction Ni-rich fractions (matte, metallichs) Convert Cu metal Roasting Electrolysis or Hydrometallurgy Nickel oxide NiO product Chlorination Reduction Ni metal (96%Ni, 1%O) Convert Ni metal Carbonylation Refined Ni metal NI>99,9998% Crundwell et al., 2011 Diaz et al., 1988 Roasting + Smelting Flash Smelting Sulfide Nickel Ore Processing and Refining
- 8. 8 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 H. Kamaruddin, et al., 2018 0 10 20 30 40 50 60 70 80 0 1 2 3 4 5 6 7 MgO, Fe2O3, SiO2 (%) Ni, Cr2O3, Al2O3 (%) Iron cap, Ferricrete Limonite Saprolite Bedrock 0.01% Co 0.15% Co 0.05% Co 0.01% Co H 2 SO 4 leach Smelting: RK-EF, BF 10 – 30 ppm Sc 50 – 300 ppm Sc BF RKEF, SEF HPAL AL, HL, Caron DNi, STAL, … Laterite Nickel Ore Processing and Refining
- 9. 9 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Pyrometallurgy vs. Hydrometallurgy Pyrometallurgy Hydrometallurgy Temperature > 300 C, burning / combustion, smelting, arcing, plasma, gas blowing, ... Temperature up to 300 C, leaching (acid, base) ... Higher reaction rates (second – minutes) Slower reaction rates (hours – years) More economical for high grade ores (High content of metal in the ore / concentrate to be recover) Suitable for low grade ores (Low to High content of metal in the ore / concentrate to be recover) Cannot recover all metals in the ore / concentrate Can recover almost all metals (valuable elements) from the ore / concentrate Unsuitable for complex ores Has flexibility to treat complex ores and produce various by product Can produce metal directly, less steps (less equipment), separation of metal and slag Metals is extracted in the form of solution and more steps are required to recover the metals from solution Recovery less than Hydrometallurgy High recovery Slag, SO2, CO2, dust emissions Handling of leach solution, tailing, SO2 from acid plant, CO2 emission from fossil fuel power plant
- 10. 10 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Metals Pyrometallurgy Hydrometallurgy Fe ~100% ~0% Al ~100% (from alumina to aluminum, pyro-electrometallurgy) ~0% (from bauxite into alumina) ~0% (from alumina to aluminum) ~100% (from bauxite into alumina) Mn ~70% (FeMn) ~30% (Mn electrolytic, chemicals) Cr ~80% (FeCr, Cr metals) ~20% (chemicals) Cu ~ 60 – 70 % ~ 30 - 40% Zn < 10% > 90% Pb > 90% < 10% Ni ~ 60% (FeNi, NPI, Ni-matte) ~ 40% (Ni, Co) Mg ~100% (pyro and fused salt electrolysis) 0% Sn 100% 0% Ti <20% (Ti sponge) / TiO2 > 80% (TiO2) Ag < 5% > 90% Au < 5% (refining < 5%) > 90% REE < 5% (refining <5%) 100% Pyrometallurgy vs. Hydrometallurgy
- 11. 11 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Laterite nickel ore Metals Challenges: • Metals content in the ore • Ore becomes more complex • Metals recovery • Plant capacity • Operating cost • Environmentally friendly process / technology (Zero Emission, Zero Waste) ? Hydrometallurgy Pyrometallurgy •HPAL •AL •HL •Caron •STAL •DNi •RKEF •Sinter EF (SEF) •BF •NPI Ni-Sulfat •Mond/Karbonil?
- 12. 12 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Rotary Kiln - Electric Furnace (RKEF) 93% Mini Blast Furnace (MBF) 6% Nippon Yakin Oheyama Process (Krupp-Renn) 1% Pyrometallurgy 80% Hydrometallurgy 20% Laterite Nickel Ore Processing Technology 1800-2000 C {O2} + <C> = {CO2} {CO2} + <C> = 2{CO} O2 O2 N2 N2 200 C 1400 C 1500 C 800 C > 1000 C CO CO CO CO FeO + {CO} = Fe + {CO2} SiO2 + 2<C> = [Si] + 2{CO} Cr2O3 + 3<C> = 2[Cr] + 3{CO} <C> = [C] H2O = {H2O} <FeCO3 >= <FeO> + {CO2} <CaCO3 >= <CaO> + {CO2} <NiO> +CO = <Ni> + {CO2} 3<Fe2O3> + {CO} = 2<Fe3O4> + {CO2} 3<Fe3O4> + {CO} = 3<FeO> + {CO2} <FeO> + {CO} = <Fe> + {CO2} 3<Fe3O4> + 4{CO} = 3<Fe> + 4{CO2} FeO Fe FeO FeO CO CO2 CO CO2 H2O CO2 CaO Fe Fe Fe Fe CO Fe3O4 Fe3O4 Fe2O3 Fe2O3 CO CO CO C C C C C C Si Ni Cr Fe Fe Fe {CO2} + <C> = 2{CO} 2{CO} = {CO2} + <C> SiO2 Cr2O3 CaS MgO Al2O3 CaO P2O5 S P MgO+SiO2+CaO+Al2O3 6-8 hours, burden from top to tuyere level Residence time of gas: 1-10 seconds or more NiO Ni <NiO> +C = <Ni> + {CO} Electric Furnace Luppen FeNi NPI NPI FeNi, Ni matte, S: Goro MHP MSP NiSO4 CoSO4 Ni Co AL HL CARON HPAL STAL DNi RKEF / Sinter EF
- 13. 13 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Nickel ore Products Limonite Saprolite Laterite Nickel Ore RKEF RKEF / RK RKEF / SEF / BF FeNi (15 – 40% Ni) NPI (8 – 15% Ni) Ni matte (78% Ni) CARON HPAL EAF/ AOD/ VOD CCM HRM AAL/HL Slab SS HRC APL / CRM CRC MHP / MSP Sinter Oxide / NOS (75-78% Ni) L – SX Ni - Sulfate Co - Sulfate FeCr, FeMn/Mn, FeSi R/EW/ER Ni Metal Co Metal Roast. Red ER Ni - Class 2 S Ni,Co - Class 1 Stainless Steel Battery, Chemicals Ni base alloys Co base alloys Special steel Catalyst Plating Other industries H2SO4 C O2 H2 H2SO4 CO,H2,NH3,CO2 Ni Briquette (Ni>97%) DNi, STAL
- 14. 14 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 ELECTRIC FURNACE FeNi/NPI Slag Granulation ID Fan Bag house Reductant Fuel Multiclone ESP ID Fan ROTARY KILN Bijih nikel basah Batubara halus Udara primer Udara sekunder ESP ID Fan ROTARY DRYER ~ 1600 C Nickel ore Fuel Rotary Kiln – Electric Furnace (RKEF)
- 15. 15 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 ELECTRIC FURNACE FeNi/NPI Slag Granulation ID Fan Bag house Reductant Fuel Multiclone ESP ID Fan ROTARY KILN Bijih nikel basah Batubara halus Udara primer Udara sekunder ESP ID Fan ROTARY DRYER ~ 1600 C Nickel ore Fuel Rotary Kiln – Electric Furnace (RKEF) ROTARY DRYER: • Reducing moisture content from ~35% to ~20 – 23%, aim to facilitate the feeding process into the rotary kiln (not sticking to conveyor belts and silo/bin walls). H2O (l) = H2O (g) H = 2.559,83 kJ/kg H2O • Moisture content in the conditioned ore (product of the rotary dryer) is kept consistently at around 20% to minimize dust formation. Coal, oil, gas, wood chips, off gas (EF/RK)
- 16. 16 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 ELECTRIC FURNACE FeNi/NPI Slag Granulation ID Fan Bag house Reductant Fuel Multiclone ESP ID Fan ROTARY KILN Bijih nikel basah Batubara halus Udara primer Udara sekunder ESP ID Fan ROTARY DRYER ~ 1600 C Nickel ore Fuel Rotary Kiln – Electric Furnace (RKEF) ROTARY KILN: •Remove residual moisture (free water) to 0% H2O. •Remove crystal water to prevent explosion in EF. •Adding coal into RK for prereduction and final reduction in EF. •Reduce about 20 – 25% NiO to Ni, Fe2O3 to FeO and 5% FeO to Fe. •Produce calcine at a temperature of ~750 – 900 °C to reduce electrical energy consumption in EF. 2FeOOH (s) = Fe2O3 (s) + H2O (g) Ni3Mg3Si4O10(OH)8 (s) = 3NiO (s) + 3MgO (s) + 4SiO2 (s) + 4 H2O (g) NiO (s) + C (s) = Ni (s) + CO (g) NiO (s) + CO (g) = Ni (s) + CO2 (g) C (s) + CO2 (g) = 2CO (g) CO + Fe2O3 (s) = 2FeO (s) + CO2 (g) Coal, oil, gas + off gas EF Coal, semicoke, wood chips, biomass
- 17. 17 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 ELECTRIC FURNACE FeNi/NPI Slag Granulation ID Fan Bag house Reductant Fuel Multiclone ESP ID Fan ROTARY KILN Bijih nikel basah Batubara halus Udara primer Udara sekunder ESP ID Fan ROTARY DRYER ~ 1600 C Nickel ore Fuel Rotary Kiln – Electric Furnace (RKEF) ELECTRIC FURNACE: • Further reduction of NiO and FeO to metallic nickel and metallic iron. • Smelting slag and ferronickel • Separation of molten slag and molten ferronickel. The density of molten ferronickel is ~7 tons/m3, density of slag is ~ 3 tons/m3. Frunace Power: 12 – 100 MW NiO (s) + CO (g) = Ni(s) + CO2 (g) FeO (s) + CO (g) = Fe(s) + CO2 (g) NiO (s) + C (s) = Ni (s) + CO (g) FeO (s) + C (s) = Fe (s) + CO (g) SiO2 (s) + 2C (s) = Si(l) + 2 CO (g) P2O5 (s) + 5C (s) = 2P(l) + 5 CO (g) Cr2O3 (s) + 3C (s) = 2Cr(s) + 3 CO (g) Ni (s) + Fe (s) = FeNi (l) Coal PP, Gas PP, Oil PP, Hydropower, nuclear power, geothermal, Renewable energy
- 18. 18 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 - 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 Ton/h EF (MW) RK ton/h RD ton/h Ferronickel furnace smelt in a day: • up to 4000 ton calcine, • 250 ton molten FeNi and, • 3700 ton molten slag. • Energy consumption around 500 kWh/ton calcine. Furnace Power RD and RK capacities
- 19. 19 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 0 1 2 3 4 5 6 7 8 9 10 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 Slag Metal Charge Charge Charge Furnace Power https://www.sec.gov/Archives/edgar/data/1322422/000119312509009939/dex99106.htm 0 1 2 3 4 5 6 7 8 9 10 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 Slag Metal Charge Charge
- 20. 20 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 S/M=1,0 S/M=2,33 S/M=1,5 S/M=1,80 SiO2/MgO Ratio N. Voermann, et al., 2004 C.M. Diaz, et al., 1988 CaO? Al2O3? Cr2O3? Slag – Refractory Interaction?
- 21. 21 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 SiO2/MgO Ratio 1350 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1 1.5 2 2.5 3 3.5 4 Slag Liquidus Temperature (C) %SiO2 / %MgO Calculated by FactSage CaO? Al2O3? Cr2O3? Slag – Refractory Interaction? 1400 1450 1500 1550 1600 1650 1700 1750 1800 1850 1 1.5 2 2.5 3 Slag Liquidus Temperature (C) %SiO2 / %MgO N. Voermann, et al., 2004 10% FeO in Slag Slag viscosity?
- 22. 22 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 S: Diaz, C.M., dkk, Ext. metallurgy of Ni & Co, 1988 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 0 5 10 15 20 25 %Si dalam lelehan logam % FeO dalam lelehan Slag FeO in slag (%) Si in metal (%) Metal – Slag Equilibrium (FeO in slag versus Si in Metal) 2FeO (slag) + Si (metal) = SiO2 (slag) + 2Fe (metal) 0 1 2 3 4 5 6 7 8 9 10 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 [CO] [CO2] FeO NiO SiO2 MgO SiO2 MgO SiO2 SiO2 [CO] C FeO C FeO NiO C C [CO] [CO] Si Si Fe Ni Fe Fe Ni C S S P2O5 P [CO] Silica reversion!!!
- 23. 23 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 0.0 0.5 1.0 1.5 2.0 2.5 0 5 10 15 20 25 %C dalam lelehan logam % FeO dalam lelehan Slag S: Diaz, C.M., dkk, Ext. metallurgy of Ni & Co, 1988 FeO in slag (%) C in metal (%) Metal – Slag Equilibrium (FeO in slag versus C in Metal) FeO (slag) + C (metal) = CO (gas) + Fe (metal) 0 1 2 3 4 5 6 7 8 9 10 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 [CO] [CO2] FeO NiO SiO2 MgO SiO2 MgO SiO2 SiO2 [CO] C FeO C FeO NiO C C [CO] [CO] Si Si Fe Ni Fe Fe Ni C S S P2O5 P [CO]
- 24. 24 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 400 600 800 1000 1200 1400 1600 0 1 2 3 4 5 6 POCHMARSKI (Carbon Steel) If %C < 0.025 Then fc = 90 If %C >= 0.025 And %C < 0.05 Then fc = 82 If %C >= 0.05 And %C < 0.1 Then fc = 86 If %C >= 0.1 And %C < 0.5 Then fc = 88.4 If %C >= 0.5 And %C < 0.6 Then fc = 86.1 If %C >= 0.6 And %C < 0.7 Then fc = 84.2 If %C >= 0.7 And %C < 0.8 Then fc = 83.2 If %C >= 0.8 And %C < 1 Then fc = 82.3 Liquidus Temperature = 1536.6 - fc * %C - (%Si * 8 + %Mn * 5 + %P * 30 + %S * 25 + %Cr * 1.5 + %Ni * 4 + %Mo * 2 + %V * 2 + %W * 2 + %Co * 1.7 + %Cu * 5 + %Nb * 2 + %Ti * 17 + %Al * 0.00051 * 10000) SUZUKI (Stainless Steel) Liquidus Temperature = 1536 - (100.3 * %C - 22.4 * %C2 - 0.16 + 13.55 * %Si - 0.64 * %Si2 + 5.82 * %Mn + 0.3 * %Mn2 + 4.2 * %Cu + 4.18 * %Ni + 0.01 * %Ni2 + 1.59 * %Cr - 0.007 * %Cr2) Calculation of Metal Liquidus Temperature https://www.tf.uni-kiel.de
- 25. 25 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Plants %FeO %SiO2 %MgO SiO2/MgO Skimming Temp. (C) Liquidus Temp. (C) Falcondo 22 46 28 1,64 1600 1560 Cerro Matoso 22 59 20 2,95 1630 – 1650 1600 Morro Do Niquel 7 50 30 1,67 1600 1550 PT Antam 5 56 29 1,93 1550 1500 Hyuga 8 52 36,4 1,43 1610 SLN 12 45 30 1,50 1620 1585 PT Inco 26 45 23,5 1,91 1550 1490 Exmibal 23 42 28 1,50 1650 1600 Plants %Ni %C %S %Si %P Skimming Temp. (C) Liquidus Temp. (C) Falcondo 36 0,02 0,15 0,04 0,03 1470 – 1500 1440 Cerro Matoso 42 0,17 0,45 1,45 0,024 1440 1405 Morro Do Niquel 18-24 1,6 0,08 3,5 0,18 1560 1360 PT Antam 21 2,25 0,24 3,4 0,018 1420-1500 1300 Hyuga 20 1,5 0,5 0,6 0,015 SLN 25 2,5 0,4 1,5 0,15 1510 1240 PT Inco 32 8-10 1360 1300 Exmibal 32 8-10 1400 1300 S: Diaz, C.M., dkk, Ext. metallurgy of Ni & Co, 1988 SLAG METAL / MATTE
- 26. 26 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 S: Diaz, C.M., et al., 1988 RKEF: Nickel Matte Production Ni-ore from mine (~1.8%Ni) Fuel / Air ROTARY DRYER ROTARY KILN ELECTRIC FURNACE Dried Ore Storage Gas to Dedusting - Stack Gas to Dedusting - Stack Coal (Reductant) Fuel / Air Sulfur Matte Granulation, Dried, Packaged (78%Ni, 21%S, Fe<0.7%) Silica Air Slag, high grade to Rotary Kiln Matte: 30%Ni, 10%S PEIRCE SMITH CONVERTER Slag
- 27. 27 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 ROTARY DRYER ROTARY KILN ELECTRIC FURNACE PEIRCE SMITH CONVERTER Fuel / Air Ni-ore Gas to Dedusting - Stack Reductant Fuel / Air Slag RKEF: FeNi & Nickel Matte Production Air Sulfur Silica Oxygen De-S De-C Oxygen %Ni %C %Si %S FeNi 22-28 1.2-1.9 1-3 0.23 FeNi 22-28 1.2-1.9 0.4-2 0.03 FeNi 24-30 0.03 0.03 0.03 Ni - Matte (78%Ni, 21%S) Crude FeNi Slag S: Diaz, C.M., et al., 1988 Gas to Dedusting - Stack Pure Ni (99,99%Ni)
- 28. 28 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 ELECTRIC FURNACE FeNi/NPI Slag Granulation ID Fan Bag house Reductant Fuel Multiclone ESP ID Fan ROTARY KILN Bijih nikel basah Batubara halus Udara primer Udara sekunder ESP ID Fan ROTARY DRYER ~ 1600 C Nickel ore Fuel Rotary Kiln – Electric Furnace (RKEF) FeNi/NPI conversion Ni-Matte CONVERTER Nickel matte Granulation Sulfur Silica Air Slag Nickel Sulfate Conversion of FeNi/NPI to Nickel Matte, due to the shortage of Class 1 Nickel for EV Battery.
- 29. 29 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 300 350 400 450 500 550 600 650 700 750 800 10 15 20 25 30 Kebutuhan Energi Listrik (kWh/ton Calcine) % Ni dalam FeNi atau NPI 25 C 100 C 200 C 300 C 800 C 700 C 600 C 500 C 400 C Ni in FeNi / NPI (%) Electrical energy consumption (kWh/ton Calcine) Electrical energy consumption 0 1 2 3 4 5 6 7 8 9 10 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 [CO] [CO2] FeO NiO SiO2 MgO SiO2 MgO SiO2 SiO2 [CO] C FeO C FeO NiO C C [CO] [CO] Si Si Fe Ni Fe Fe Ni C S S P2O5 P [CO]
- 30. 30 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 SINTERING ELECTRIC FURNACE Ferronickel /NPI Slag ID Fan Granulation INGOT CASTER Container Nickel ore Lime Semi coke Gas / Oil Sinter ore Reductant (Semi coke) Sintering – Electric Furnace (SEF)
- 31. 31 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Electric Furnace Slab NPI (molten) NPI (molten) FeCr (molten) Mn elect. Cold Rolling Mill CRC HRC Hot Strip Mill Molten NPI, molten FeCr, no Fe Scrap MOST EFFICIENT STAINLESS STEEL PLANT IN THE WORLD 4 x RKEF 4 x RKEF 4 x RKEF 4 x RKEF 4 x RKEF FeSi FeMn Integration of Nickel Smelting Plant and Stainless Steel Plant
- 32. 32 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Si 40.7% Cr 3.0% Mg 47.7% Sc 4.5% Ni 1.0% Co 0.4% Fe 2.8% 843,4 USD/ton Terak Fe 15% Ni 71% Co 4% Sc 10% 304,2 USD/ton bijih nikel kering 400 - 550 kg Slag 60 - 120 kg FeNi / NPI 1 Ton Nickel ore (Wet) dry nickel ore Slag Extraction of valuable metals from slag INDONESIA: ~ 70 mio. Tons nickel ore/year
- 33. 33 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 CO2 emission Sumber: http://berkeleyearth.org/ https://www.iea.org/reports/net-zero-by-2050 Balance between the amount of greenhouse gas produced and the amount removed from the atmosphere
- 34. 34 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Thermodynamic: Exothermic & Endothermic H < 0 → Exothermic Reaction (Produce Heat) H > 0 → Endothermic Reaction (Require Heat) https://teachsciencewithfergy.com 6 CO2(g) + 6 H2O(l) → C6H12O6(s) + 6 O2(g) H = +2816 kJ C6H12O6(s) + 6 O2(g) → 6 CO2(g) + 6 H2O(l) H = -2816 kJ Our bodies derive energy from the combustion of glucose (a sugar) Plants make glucose in photosynthesis the reaction reaction of CO2 with H2O. The energy needed is supplied by the sun.
- 35. 35 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 ELECTRIC FURNACE FeNi/NPI Slag Granulation ID Fan Bag house Reductant Fuel Multiclone ESP ID Fan ROTARY KILN Bijih nikel basah Batubara halus Udara primer Udara sekunder ESP ID Fan ROTARY DRYER ~ 1600 C Nickel ore Fuel Rotary Kiln – Electric Furnace (RKEF) CO2 CO2 CO2 CO2 from Power plants: Coal, Oil, Gas, Biomass To DO: • Replace carbonaceous materials with hydrogen for reductant and fuel. • Renewable energies for power generation (hydrogen gas production and smelting in EF) • Smelting of calcine in EF (?) • Use plasma instead of arcing with graphite electrode (?) • Alternative technologies? High temperature electrolysis? Carbonyl/Mond? • ….
- 36. 36 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Blast Furnace Blast Furnace Sintering Coking Plant (heat recovery) Nickel ore + burned lime + coke breeze Mixer Hot stove Blower Sinter ore Bins Coking coal Coke Stack Power plant Boiler CaF2 Slag NPI (Nickel pig iron) Granulation Pig casting BLAST FURNACE sinter pelet bongkahan bijih besi kokas pelet bongkahan bijih besi udara batubara halus besi tua oksigen besi wantah (pig iron) oksigen besi tua oksigen BF BOF BOF SMELTINGREDUCTION DIRECT REDUCTION DAURULANG BESI TUA besi wantah (pig iron) COREX FINEX bijih besi halus pelet bongkahan bijih besi bijih besi halus batubara SF(MIDREX, HyL) RHF (Fastmet, Inmetco, ITmk3) RK (SL/RN, Krupp-Codir, DRC, ACCAR/ OSIL, TDR, Jindal) FB (Finmet, Circofer) gas reduktor besi tua besi tua besi spons (DRI, HBI) EAF EAF Lump ore Sinter ore Pellet Pellet Coke Hot blast PCI Pellet Hot metal Oxygen Scrap
- 37. 37 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 200°C 800°C > 1000°C H2O = {H2O} 3<Fe2O3> + {CO} = 2<Fe3O4> + { 3<Fe3O4> + {CO} = 3<FeO> + <FeO> + {CO} = <Fe> + {CO 3<Fe3O4> + 4{CO} = 3<Fe> + 2{CO} = {CO2} + <C> <NiO> + {CO} = <Ni> + {CO2} 1800-2000°C O2 O2 N2 N2 1400°C 1500°C CO CO CO CO FeO + {CO} = Fe + SiO2 + 2<C> = [Si] + 2{CO} MnO + <C> = [Mn] + [S] + (CaO) + C = (C <C> = [C] <FeCO3 >= <FeO> + {CO2} <CaCO3 >= <CaO> + {CO2} <MgCO3 > = <MgO> + {CO2} FeO Fe FeO FeO CO CO2 CO CO2 H2O CO2 CaO Fe Fe Fe Fe CO Fe3O4 Fe3O4 Fe2O3 Fe2O3 CO CO CO C C C C C C Si Mn Fe Fe Fe {CO2} + <C> = 2{CO NiO Ni 0 1 2 3 4 5 6 7 8 9 10 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 FeO NiO SiO2 MgO SiO2 [CO] C C FeO C [CO] [CO] Si Fe Ni Fe C P2O5 P [CO] 2000°C 2000°C ~1650°C 700-1100°C Electric Furnace vs Blast Furnace
- 38. 38 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Blast Furnace 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 1200m3 3600m3 6000m3 450 m3 210m3 75m3 20m3 1800 m3 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 Iron Ore Limonite nickel ore Saprolite nickel ore
- 39. 39 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Krupp Renn S: H. Arai, et al. 1990 Tsuji, Tachino, 2012 Rotary Kiln: 3,6 m , 72 m L, slope 2% 50-60 rph T max: 1400°C Recovery nikel dapat mencapai ~91% Ore Aerofall mill Hot air Tube mill Silo Slurry tank Drum filter Pug mill Rod mill Briquetting machine Rotary kiln Preheater Water pit Mercy mill Screen Jig Jig Classifier Magnetic separator Limestone Anthracite Water FeNi luppen Sand Tailing to dump To Kiln feed Pretreatment Smelting Separation
- 40. 40 Zulfiadi Zulhan MG-4025 Sustainable Process Metallurgy 2021 Thank You! Zulfiadi Zulhan Department of Metallurgical Engineering Faculty of Mining and Petroleum Engineering Bandung Institute of Technology Jl. Ganesa No. 10 Bandung, 40132 INDONESIA Email: zulfiadi.zulhan@gmail.com