PRODUCTION OF HOT METAL FROM A TITANIUM-CONTAINING IRON SAND BY USING INDUCTION FURNACE Adil Jamali, Indonesian Institute of Sciences, - LIPI Experiments to produce hot metal from Iron sand containing +/- 7% titanium dioxide were carried out by forming a composite pellet of iron sand, karbon and bentonite , reducing the pellet in a low shaft furnace and finally melting the reduced pellet in a five hundred kilograms induction furnace. Titanium was separated from hot metal into slag by adjusting slag composition.. The slag produced was tapped at minimum temperature 1400 degree C. The hot metal was adjusted in the furnace to obtain a white, grey or alloyed pig iron.

1. HOT METAL PRODUCTIONHOT METAL PRODUCTION
FROM A TITANIUM CONTAININGFROM A TITANIUM CONTAINING
IRON SANDIRON SAND
Adil Jamali, Eng., M.Sc.Adil Jamali, Eng., M.Sc.
WAITRO-CMRDI WORKSHOP ON NEW TRENDS IN MINERAL PROCESSING
22-25 JANUARY 2006, Cairo, Egypt. -

2. IntroductionIntroduction
Indonesian SteelIndonesian Steel
Production (2005)Production (2005) : 4.4 M.Ton: 4.4 M.Ton
Consumption (2004) : 22 kg/cap-yearConsumption (2004) : 22 kg/cap-year
Raw MaterialRaw Material
Hemato MagnetiteHemato Magnetite :small and:small and
scattered 15 M.Tonscattered 15 M.Ton
Iron Sand containing TiOIron Sand containing TiO22 165 M.Ton165 M.Ton
Lateritic Iron Ore 974 M.TonLateritic Iron Ore 974 M.Ton
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3. Iron SandIron Sand
Raw MaterialRaw Material Conc.Conc.
FeFe 12.5 %12.5 % 58 %58 %
MnOMnO22 0.6 %0.6 %
AlAl22OO33 7.6 %7.6 % 3.6 %3.6 %
CaOCaO 13.2 %13.2 % 1.5 %1.5 %
MgOMgO 7.7 %7.7 % 2.4 %2.4 %
NaNa22OO 0.03 %0.03 %
KK22OO 0.18 %0.18 %
SiOSiO22 34.4 %34.4 % 2.5 %2.5 %
TiOTiO22 1.9 %1.9 % 8.5 %8.5 %
PP 0.3 %0.3 % 0.13 %0.13 %
SS 0.04 %0.04 % 0.06 %0.06 %
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4. ProblemsProblems
How to produce iron from iron sandHow to produce iron from iron sand
TiOTiO22 : 7 – 12 %: 7 – 12 %
VanadiumVanadium
Use the available technology /Use the available technology /
equipmentequipment
HYL – EAFHYL – EAF
Induction FurnaceInduction Furnace
Small – medium scaleSmall – medium scale
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5. Hot MetalHot Metal
ExperimentExperiment
SpongeSponge
Pellet CompositePellet Composite
PelletizerPelletizer
MixerMixer
ReductionReduction
in Shaft Kilnin Shaft Kiln
Melting ShaftMelting Shaft
FurnaceFurnaceSlagSlag
Hot MetalHot Metal
SlagSlag
BentoniteBentoniteCoalCoal Iron SandIron Sand
Melting in InductionMelting in Induction
FurnaceFurnace
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6. Separation of TiOSeparation of TiO22
TiOTiO22 SlagSlag
MMTT = 1400= 1400 ˚˚CC
Slag composition adjustmentSlag composition adjustment
TiOTiO22 ::
SiOSiO22 ::
CaOCaO ::
to satisfy the TiOto satisfy the TiO22 – SiO – CaO liquid at– SiO – CaO liquid at
T = 1400T = 1400 ˚˚C in the phase diagramC in the phase diagram
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7. TiOTiO22 – SiO– SiO22 – CaO Phase Diagram– CaO Phase Diagram
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8. Experiment Result (I)Experiment Result (I)
I. Sponge iron from shaft furnaceI. Sponge iron from shaft furnace
∅∅ = 400 mm= 400 mm h = 1500 cmh = 1500 cm
Fe %Fe % Wt %Wt %
Pellet spongePellet sponge : 80 %: 80 % 45 %45 %
Fine SpongeFine Sponge : 86 %: 86 % 35 %35 %
Sintered SpongeSintered Sponge : 67 %: 67 % 20 %20 %
II. Slag can be tapped at TII. Slag can be tapped at T ±± 14001400 ˚˚CC
from shaft furnace and inductionfrom shaft furnace and induction
furnacefurnace
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9. Experiment Result (II)Experiment Result (II)
III. Hot Metal compositionIII. Hot Metal composition
from induction furnacefrom induction furnace
FeFe = 93.9 %= 93.9 %
SiSi = 1.81 %= 1.81 %
MnMn = 0.8 %= 0.8 %
PP = 0.027 %= 0.027 %
SS = 0.08 %= 0.08 %
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10. Why Induction Furnace ?Why Induction Furnace ?
FamiliarityFamiliarity
Lower power consumptionLower power consumption
Easy to adjust metalEasy to adjust metal
compositioncomposition
Small scaleSmall scale
End product from ore isEnd product from ore is
possiblepossible
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11. ConclusionConclusion
1.1. Hot metal can be produced from ironHot metal can be produced from iron
sand containingsand containing ±± 8 % Titanium Dioxide8 % Titanium Dioxide
by three processing steps :by three processing steps :
Production of composite pelletProduction of composite pellet
Reduction in shaft furnaceReduction in shaft furnace
Melting in induction furnaceMelting in induction furnace
1.1. Titanium can be separated into slagTitanium can be separated into slag
that flow atthat flow at ±± T = 1400T = 1400 ˚˚CC
2.2. The prospect of producing “end product”The prospect of producing “end product”
is now open directly from iron sandis now open directly from iron sand
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12. Thanks to :Thanks to :
WAITROWAITRO
CMRDICMRDI
Workshop ParticipantsWorkshop Participants
Organization committeeOrganization committee

13. HOT METAL PRODUCTIONHOT METAL PRODUCTION
FROM A TITANIUM CONTAININGFROM A TITANIUM CONTAINING
IRON SANDIRON SAND
• IntroductionIntroduction
• Iron SandIron Sand
• ProblemsProblems
• ExperimentExperiment
• Separation of TiO2Separation of TiO2
• TiO2 – SiO2 – CaOTiO2 – SiO2 – CaO
Phase DiagramPhase Diagram
• Experiment Result (I)Experiment Result (I)
• Experiment Result (II)Experiment Result (II)
• Why Induction Furnace ?Why Induction Furnace ?
• ConclusionConclusion

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